Spring Clip Bus Bar Attachment for Battery Terminals
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Solution Overview
Problem
Misalignment of battery cell terminals during bus bar welding leads to inconsistent electrical connections due to manufacturing variations, requiring excessive force for deformation to achieve proper welding gaps.
Innovation Solution
A bus bar clip assembly with spring-loaded legs that biases the bus bar against the terminals, ensuring consistent pressure and alignment for effective welding, even in misaligned configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the bus bar is forcibly deformed towards the terminals to achieve proper welding gap, then the welding quality is improved, but the force required increases and may damage the bus bar or terminals
Solution Approach 1:
The clip is pre-assembled onto the bus bar before the welding process, establishing the correct positioning and gap control in advance. This preliminary action eliminates the need for forceful deformation during welding, as the clip maintains the bus bar in the proper position relative to the terminals throughout the welding process.
Solution Approach 2:
The clip acts as an intermediary component between the bus bar and the terminals. It provides mechanical support and positioning, allowing the bus bar to maintain consistent spacing from the terminals without requiring excessive deformation force. The clip mediates the connection by holding the bus bar in the correct position.
2Reliability
If the bus bar properties (material type and mass) are optimized for electrical transmission, then the electrical conductivity is improved, but the force required for deformation increases
Solution Approach 1:
The clip is installed on the bus bar before welding to establish proper positioning. This preliminary action allows the bus bar to maintain its optimized material properties and mass for electrical transmission without requiring subsequent deformation, as the clip handles the positioning function.
Solution Approach 2:
The clip serves as an intermediary that handles the mechanical positioning task, allowing the bus bar to focus on its primary function of electrical transmission. The bus bar's mass and material properties are optimized for conductivity rather than mechanical deformation.
3Device complexity
If the terminals are arranged in a row for efficient connection, then the assembly simplicity is improved, but the alignment variations between terminals increase
Solution Approach 1:
The clip is divided into multiple legs, with each leg engaging with individual terminals in the row. This segmentation allows each leg to independently accommodate alignment variations of specific terminals while maintaining overall connection integrity. The bus bar with its clip can efficiently connect multiple terminals in a row despite manufacturing variations in their positions.
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 clip assembly ensures proper welding by maintaining the necessary gap between the bus bar and terminals, enhancing electrical connectivity and reducing the force required for deformation, thus improving the reliability of battery connections.
Implementation Method 1
A clip, having a spring portion integrally formed with first and second legs extending therefrom... wherein the spring portion biases the first and second legs towards opposed sides of the first and second terminals
Implementation Method 2
The bus bar is commonly welded to the face of the terminals to achieve effective electrical transmission... At least one of the first and second legs is welded to the first and second terminals
Data Source
AI summary
An assembly connecting a battery bus bar to battery cell terminals, with the bus bar provided with spring clips. The clips fit over the battery terminals and hold the bus bar and terminals in contact, with welding attaching the clip to the terminals.