Spring Clip Bus Bar Connector for Automotive Electrical Distribution
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Solution Overview
Problem
Existing electrical distribution systems in motor vehicles require special tools and precise tolerances for reliable interconnection of bus bars, making them complex and costly to assemble.
Innovation Solution
A bus bar connector system using a spring clip with angled longitudinal arms to apply contact force between bus bars, allowing for intuitive assembly without specialized tools and accommodating positional tolerance, ensuring reliable electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fasteners such as bolts and nuts or rivets are used to interconnect bus bars, then reliable electrical connection is achieved, but special tools and precise tolerances are required, increasing assembly complexity
Solution Approach 1:
The patent replaces traditional mechanical fastening systems (bolts, nuts, rivets) with a spring-based elastic connection system. The spring clip applies continuous contact force to maintain intimate electrical contact between bus bars without requiring threaded fasteners or precise alignment tolerances, thereby eliminating the need for special assembly tools while ensuring reliable electrical connection.
Solution Approach 2:
The invention changes the connection mechanism from rigid mechanical fastening to elastic deformation. The spring clip utilizes elastic parameters to provide continuous contact force that accommodates manufacturing tolerances and thermal expansion, maintaining reliable electrical connection without requiring precise assembly tolerances or special tools.
2Ease of manufacture
If interference fitting of bus bars is used, then connection without special tools is achieved, but precise tolerances of mating features are required, increasing manufacturing complexity
Solution Approach 1:
The spring clip serves as an intermediary element between the bus bars, providing the connection function without requiring precise interference fitting features on the bus bars themselves. The elastic spring accommodates dimensional variations and tolerances in the bus bar manufacturing while maintaining reliable electrical contact, thereby simplifying manufacturing requirements.
3Reliability
If traditional bus bar connection systems are used, then reliable electrical connection is achieved, but very precise placement is required for alignment with electrical contacts, increasing assembly difficulty
Solution Approach 1:
The spring clip introduces dynamic elasticity to the connection system, allowing for automatic adjustment and self-alignment. The elastic deformation capability of the spring arms enables the connection to accommodate misalignment and maintain intimate contact between bus bars and electrical contacts without requiring very precise placement during assembly.
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 spring clip system provides a high current interface with reduced assembly complexity and cost, allowing for easier integration and alignment of bus bars while maintaining effective electrical conductivity and resistance to thermal expansion and vibration.
Implementation Method 1
a spring clip configured to apply a contact force to the first and second bus bars effective to bring at least a portion the first and second bus bars into intimate contact with one another
Data Source
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AI summary
A bus bar connector system (22) and an electrical distribution center (10) suitable for use in a motor vehicle including such a bus bar connection system is presented. The bus bar connector system (22) includes a first bus bar (18A), a second bus bar (18B), and a spring clip (26) configured to apply a contact force to the first and second bus bars (18A, 18B) effective to bring at least a portion the first and second bus bars (18A, 18B) into intimate contact with one another. The spring clip (26) may comprise two longitudinal spring arms (28) each extending from a lateral spring base (30) interconnecting the spring arms (28). These spring arms (28) are angled toward one another and end portions of the spring arms (28) may be angled away from one another, thereby forming an hourglass or X-shaped spring clip (26). The end portions of the spring arms (28) may be configured to retain the spring clip (26) within a slot (24) defined by a connector housing (20).