Spring-Clamped Battery Busbar Connection Device
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Solution Overview
Problem
Current battery connection technologies for electric and hybrid motor vehicles, which rely on screw and nut systems for busbars, face challenges such as increased assembly time, risk of poor connections, and limited flexibility due to tolerance issues, leading to potential quality problems and high costs.
Innovation Solution
A power connection device featuring a busbar with cages and contact pads, utilizing elastic means like spring leaves to securely hold conductive tabs against contact pads without the need for screws, allowing for flexible accommodation of cell tolerances and improved electrical conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the number of interconnected battery cells is increased to increase vehicle autonomy, then the energy storage capacity is improved, but the assembly time increases and the risk of poor connections increases due to more nuts and screws required
Solution Approach 1:
The patent replaces the traditional mechanical screw-and-nut fastening system with a spring-based elastic clamping mechanism. The spring leaf automatically clamps the busbar to the battery cell terminal through elastic force, eliminating the need for multiple screws and nuts. This substitution dramatically reduces assembly time while maintaining reliable electrical connections, directly resolving the contradiction between increased cell quantity (for higher energy capacity) and assembly time consumption.
Solution Approach 2:
The spring-based clamping mechanism is self-adjusting and self-securing. The elastic spring automatically applies clamping force to maintain electrical contact between the busbar and battery terminal, compensating for tolerance variations without requiring precise manual adjustment of multiple fasteners. This self-service characteristic reduces assembly complexity and time while ensuring consistent connection quality across increased numbers of cells.
2Use of energy by moving object
If the number of interconnected battery cells is increased to increase vehicle autonomy, then the energy storage capacity is improved, but the connection reliability deteriorates due to increased risk of poorly screwed busbars
Solution Approach 1:
The patent replaces the mechanical screw-and-nut fastening system with a spring-based elastic clamping mechanism. The spring leaf automatically clamps the busbar to the battery cell terminal through elastic force, eliminating the need for multiple screws and nuts. This substitution dramatically reduces assembly time while maintaining reliable electrical connections, directly resolving the contradiction between increased cell quantity (for higher energy capacity) and assembly time consumption.
Solution Approach 2:
The invention changes the fundamental parameter of connection force application from discrete, manually-controlled screw torque to continuous, elastic spring force. The spring maintains constant clamping pressure that automatically compensates for dimensional tolerances and thermal expansion, ensuring stable electrical contact. This parameter change transforms the connection reliability from being torque-dependent to being elastic-force-dependent, significantly reducing the risk of poor connections even as the number of cells increases.
3Strength
If a screw and nut system is used to fasten busbars onto battery cells, then the mechanical strength of connection is improved, but the flexibility in accommodating tolerance variations deteriorates
Solution Approach 1:
The invention changes the fundamental parameter of connection force application from discrete, manually-controlled screw torque to continuous, elastic spring force. The spring maintains constant clamping pressure that automatically compensates for dimensional tolerances and thermal expansion, ensuring stable electrical contact. This parameter change transforms the connection reliability from being torque-dependent to being elastic-force-dependent, significantly reducing the risk of poor connections even as the number of cells increases.
Solution Approach 2:
The spring-based clamping mechanism introduces dynamic adaptability to the connection system. Unlike rigid screw fastening, the elastic spring can dynamically adjust its clamping force in response to tolerance variations, thermal expansion, and mechanical deformations. This dynamic characteristic provides inherent flexibility in accommodating manufacturing tolerances while maintaining secure electrical connections, eliminating the need for precise tolerance control.
4Strength
If a screw and nut system is used to fasten busbars onto battery cells, then the mechanical strength of connection is improved, but the assembly complexity increases due to controllable parameters such as number of screw turns and screwing torques
Solution Approach 1:
The patent replaces the mechanical screw-and-nut fastening system with a spring-based elastic clamping mechanism. The spring leaf automatically clamps the busbar to the battery cell terminal through elastic force, eliminating the need for multiple screws and nuts. This substitution dramatically reduces assembly time while maintaining reliable electrical connections, directly resolving the contradiction between increased cell quantity (for higher energy capacity) and assembly time consumption.
Solution Approach 2:
The spring-based clamping mechanism is self-adjusting and self-securing. The elastic spring automatically applies clamping force to maintain electrical contact between the busbar and battery terminal, compensating for tolerance variations without requiring precise manual adjustment of multiple fasteners. This self-service characteristic reduces assembly complexity and time while ensuring consistent connection quality across increased numbers of cells.
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
This solution reduces assembly time, enhances connection reliability, and improves flexibility in accommodating cell positioning tolerances, thereby ensuring robust and efficient electrical connections while minimizing the risk of quality issues and costs.
Implementation Method 1
elastic means (these elastic means comprise for example a spring leaf extending away from one of the walls and designed to retain and compress the elements inserted in the cage against each other)
Implementation Method 2
Each contact pad is made from an electrically conductive metal. Each contact pad is inserted in an opening formed in the busbar... An electrical connection is thus formed between the tab and the busbar, by the intermediary of the contact pad
Data Source
Figure 1~3
Figure 4~5
Figure 6~8
AI summary
The power connection device of an electric battery comprises a cage (5), a busbar (4) and a contact pad (23). The cage (5) is made from a first material chosen for its mechanical properties and its rigidity in particular. The busbar (4) and the pad (23) are made from a second material chosen for its electrical conduction properties. The cage (5) also comprises spring means (13) designed to clamp at least a portion of a tab (15), inserted into the cage (5), against the pad (23). Connection assembly comprising this device and a tab (15) electrically connected to a battery cell.