Self-aligning Busbar Assembly with Flexible Tabs
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Solution Overview
Problem
Conventional busbar assemblies are rigid and do not allow for adjustments in tolerances during assembly, requiring multiple connectors and increasing packaging size and assembly time, while maintaining sealing integrity is a challenge.
Innovation Solution
A self-aligning busbar assembly with a housing, busbar, and a front holder that includes flexible tabs and angular retention features, allowing for movement to accommodate assembly variances and maintain sealing integrity through a seal between the busbar and housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional single-threaded busbar design is used, then structural simplicity is maintained, but rigidity increases and tolerance adjustment capability is lost
Solution Approach 1:
The busbar is transformed from a rigid single-threaded structure to a multi-threaded flexible structure that can dynamically adjust its position and orientation within the holder to accommodate assembly tolerances and component variances
Solution Approach 2:
The busbar's physical state is changed by introducing multiple threads and flexible sections, allowing it to bend and conform to different positions while maintaining electrical connection, thus adapting to tolerance variations in the assembly
2Adaptability or versatility
If multiple busbar connectors are used to accommodate tolerances, then alignment flexibility is improved, but packaging size and assembly time increase
Solution Approach 1:
Multiple busbar connectors are merged into a single integrated multi-threaded busbar structure that provides the same alignment flexibility through its flexible sections, reducing the number of separate components and simplifying assembly
Solution Approach 2:
The multi-threaded busbar serves multiple functions simultaneously: it provides electrical connection, accommodates tolerance variations, enables self-alignment, and reduces assembly complexity, replacing what would otherwise require multiple separate connectors
3Stability of the object's composition
If busbar is made rigid for structural stability, then manufacturing precision is maintained, but sealing integrity during assembly becomes difficult to maintain
Solution Approach 1:
The busbar transitions from a completely rigid structure to a semi-flexible structure with controlled flexibility in specific sections, allowing it to adapt to assembly variations while maintaining overall structural stability and sealing integrity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables flexible alignment and secure connection of busbars during assembly, reducing assembly time and maintaining sealing integrity between electrical components like a motor and inverter module.
Implementation Method 1
at least one flexible tab extending inwardly from the inner wall into the busbar receiving aperture. The at least one flexible tab is configured to bias and center the at least a portion of the busbar within the busbar receiving aperture
Data Source
Figure 1~2
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AI summary
A self-aligning busbar assembly (10) includes a housing (40), a busbar (42) having a first terminal connecting end (90), a second terminal connecting end (92), and a jog portion (94) disposed therebetween, and a front holder (44) coupled to the housing (40) and the busbar (42). The front holder (44) includes an inner wall (124) defining a busbar receiving aperture (126) to receive at least a portion of the busbar (42), and at least one flexible tab (134) extending inwardly from the inner wall (124) into the busbar receiving aperture (126). The at least one flexible tab (134) is configured to bias and center the at least a portion of the busbar (42) within the busbar receiving aperture (126). At least one clearance is defined in the busbar receiving aperture (126) between the inner wall (124) and the busbar (42) and is configured to enable at least one of the first and second terminal connecting ends (90, 92) to move to account for tolerances and/or variances during installation of the busbar assembly (10).