Slidable Screw Module Connector for Position-Tolerant Busbar Assembly
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Solution Overview
Problem
Conventional module connectors for electric modules, such as battery modules in electric vehicles, face challenges in accommodating positional tolerances without applying excessive force, as flexible conductor sections often require bending and have limited flexibility due to their length.
Innovation Solution
A module connector design featuring a busbar with a through opening and a rotatable, slidably parallel screw mechanism, assisted by a screw guide, allows for adjustable alignment and secure connection of electric modules, compensating for positional tolerances without high force application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If flexible conductor sections are used to compensate for positional tolerances, then adaptability to different relative positions is improved, but device complexity and mechanical stress increase due to bending requirements
Solution Approach 1:
The connector is divided into separate functional components: a rigid busbar section for stable electrical connection and a separate flexible conductor section for position compensation. This segmentation allows each part to optimize its function without compromising the other, reducing overall device complexity while maintaining adaptability.
Solution Approach 2:
A flexible conductor section acts as an intermediary element between the rigid busbar and the module terminals. This intermediary component absorbs positional variations through its flexibility while transmitting electrical current, thereby decoupling the rigid structural requirements from the flexible positioning requirements.
2Device complexity
If flexible conductor sections are made shorter to reduce complexity, then device complexity is reduced, but adaptability to positional tolerances deteriorates
Solution Approach 1:
Flexibility is concentrated locally at the flexible conductor section, while the busbar and terminal connection points maintain rigid structural quality. This localized flexibility allows the system to achieve high adaptability with minimal overall complexity, as only the necessary flexible portion is designed with complex geometry.
3Strength
If high force is applied to bend flexible conductor sections, then secure connection is improved, but mechanical stress and risk of damage increase
Solution Approach 1:
The flexible conductor section is designed to dynamically adapt to positional variations during installation without requiring excessive forcing. Its inherent flexibility allows it to conform to misaligned positions through controlled deformation rather than forced bending, reducing peak mechanical stresses while maintaining connection integrity.
Data Source
AI summary
A module connector for electrically connecting two electric modules comprises a busbar, at least one screw and at least one screw guide. The busbar includes at least one flat face defining a busbar plane, and a through opening extending perpendicularly to the busbar plane and through the busbar. The at least one screw is held in the through hole, rotatable relative to the busbar and slidable parallel to the busbar plane. The at least one screw guide is rotatable relative to the busbar and held at least sectionally in the through opening. The at least one screw guide includes a hole extending parallel to the through opening in which the at least one screw is held at least sectionally.