Split-Insert Busbar Fixing for Vibration and Shock Stability
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Solution Overview
Problem
Existing connector systems for busbar conductors in electric and hybrid vehicles face issues with reliable and flexible fixation under environmental influences such as temperature variations, moisture, dust, vibrations, and shocks, and are cumbersome to assemble, leading to potential disconnection and increased assembly time and costs.
Innovation Solution
A connector system comprising a clamping frame with an elastic insert that is partially split at the aperture, allowing easy assembly and deformation to securely hold conductors, and a u-shaped component with a closing member for pressure application, providing a firm and adaptable fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid fixing means are used to fix busbar conductors to vehicle parts, then mechanical connection strength is improved, but reliability under environmental influences (vibrations, shocks, temperature variations) deteriorates
Solution Approach 1:
The patent changes the physical state of the fixing means from rigid to elastic/deformable. The elastic insert is designed to deform under external impacts such as vibrations, shocks, and temperature variations, allowing it to maintain reliable electrical and mechanical connections under environmental influences while still providing sufficient fixing strength.
Solution Approach 2:
The patent employs a composite structure consisting of a rigid clamping frame combined with an elastic insert material. This composite design allows the rigid frame to provide structural support and the elastic material to absorb environmental stresses, thereby achieving both mechanical strength and reliability under vibrations and shocks.
2Device complexity
If rigid connectors are used for fixing busbar conductors, then assembly structure simplicity is improved, but ease of assembly deteriorates due to cumbersome assembly process
Solution Approach 1:
The patent introduces a dynamic element - the elastic insert that can deform during assembly. The split aperture design allows the insert to be opened for easy conductor insertion and then automatically closes to secure the conductor, eliminating complex assembly steps while maintaining structural simplicity.
Solution Approach 2:
The patent segments the aperture into two movable parts connected by a hinge, allowing the aperture to open and close. This segmentation enables easy insertion and removal of conductors without requiring complex tools or procedures, thereby improving ease of assembly while keeping the overall structure simple.
3Ease of manufacture
If fixed aperture design is used in fixing means, then manufacturing simplicity is improved, but adaptability for different conductor sizes and shapes deteriorates
Solution Approach 1:
The patent transforms the fixed aperture into a dynamic, adjustable aperture using an elastic insert with a hinge mechanism. The aperture can open to accommodate various conductor sizes and shapes, then close to secure them firmly. This dynamic design provides versatility for different conductors while maintaining manufacturing simplicity through a single integrated component.
4Reliability
If conventional fixing means are used, then electrical connection reliability is compromised under vibrations and shocks, but adding vibration dissipation mechanisms increases device complexity
Solution Approach 1:
The patent changes the mechanical properties of the fixing means from rigid to elastic, allowing the insert to deform and absorb vibration energy. This parameter change enables the fixing means to dissipate vibrations and maintain reliable electrical connections without adding complex vibration isolation mechanisms.
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
The system ensures reliable and flexible fixation of conductors, reduces assembly errors, and is cost-effective, while withstanding environmental impacts and high-voltage requirements, simplifying the assembly process and improving manufacturability.
Implementation Method 1
an elastic insert, adapted to be arranged within the clamping frame; wherein the insert comprises a first aperture for receiving a conductor, and wherein the insert is at least partially split at the first aperture, which allows the first aperture to be opened for receiving the conductor
Data Source
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AI summary
The present invention relates to a connector system for fixing one or more conductors, such as busbar conductors, the connector system comprising: a clamping frame, configured to be fixed to a body, such as a vehicle; and an elastic insert, adapted to be arranged within the clamping frame; wherein the insert comprises a first aperture for receiving a conductor, and wherein the insert is at least partially split at the first aperture, which allows the first aperture to be opened for receiving the conductor.