Sealed Busbar Connector Assembly for EV Power Distribution
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Solution Overview
Problem
Conventional power distribution components in motor vehicles face challenges such as space constraints, harsh operating conditions, and high failure rates due to incorrect installation and dislodgment, leading to significant repair and warranty costs.
Innovation Solution
A connector system with a sealed and grounded electrical connection, featuring a male connector assembly and an adaptor assembly with a female terminal assembly, including a capacitor assembly and a busbar with a grounding coupler, designed for reliable operation in high-stress applications, eliminating the need for bolted connections and reducing electromagnetic noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If custom fabricated busbars are used with conventional fasteners, then electrical connection is achieved, but installation becomes extremely difficult and time-consuming due to protective equipment requirements
Solution Approach 1:
The patent replaces conventional mechanical fastening systems (bolts, nuts, washers, studs) with a push-button activation mechanism. The installer simply pushes a button to activate the busbar connection, eliminating the need for complex mechanical assembly and the protective equipment it requires. This substitution maintains reliable electrical connection while dramatically simplifying installation.
Solution Approach 2:
The busbar system incorporates self-aligning and self-securing features that automatically position and secure the electrical connection without requiring manual intervention for alignment or fastening. The system serves itself by automatically establishing the electrical connection when activated, reducing installation complexity and time.
2Reliability
If custom fabricated busbars are used, then power distribution is achieved, but any alterations require altering busbar configuration which is expensive and time-consuming
Solution Approach 1:
The busbar system is divided into modular, interchangeable components that can be easily reconfigured by swapping segments rather than altering the entire busbar structure. This segmentation allows for flexible adaptations to different power distribution needs without requiring expensive and time-consuming custom fabrication work.
Solution Approach 2:
The busbar design incorporates universal mounting interfaces and standardized connection points that can accommodate various configurations and applications. This multi-functionality allows the same busbar system to serve different power distribution requirements without custom fabrication, enhancing adaptability while maintaining reliable electrical connections.
3Strength
If conventional fasteners are used to couple busbars, then mechanical connection is achieved, but the configuration makes installation extremely difficult in high-stress applications
Solution Approach 1:
The patent replaces the complex mechanical fastening system with a simplified push-button activation mechanism that achieves secure mechanical connection without requiring multiple fasteners, alignment procedures, or protective equipment. The button activation triggers an automatic securing mechanism that provides strong mechanical connection with minimal installer effort.
Solution Approach 2:
The push-button mechanism serves as an intermediary that translates a simple user action into a complex securing operation. When the button is pressed, it activates the busbar's internal mechanism to automatically align, secure, and verify the mechanical connection, bridging the gap between simple operation and strong connection.
4Reliability
If custom fabricated busbars are installed, then electrical connection is established, but they are prone to high failure rates due to their configuration
Solution Approach 1:
The busbar system incorporates pre-engineered features that cushion against potential failure modes before they occur. This includes built-in stress relief elements, redundant connection paths, and protective coatings that prevent degradation from vibration and environmental factors, thereby maintaining connection stability and reducing failure rates in high-stress applications.
Data Source
AI summary
The present disclosure relates to a connector system that provides a sealed and grounded electrical connection for a component of a power management system, like those found in a battery-powered motor vehicle. The connector system includes a male connector assembly and an adaptor assembly. The adaptor assembly includes: (i) a capacitor assembly, (ii) a female terminal assembly, and (iii) a busbar assembly. An internal electrical connection state is defined when: (a) the female terminal assembly is electrically coupled to the capacitor assembly, (b) the capacitor assembly is electrically coupled to the busbar assembly, and (c) the busbar assembly is electrically coupled to an extent of the component of the power management system. In the internal electrical connection state, the electrical couplings are sealed from the external environment which increases the operating life, durability and reliability of the adaptor assembly, the connector system and the power management system component.