Spring-Contact Busbar Assembly for Easier Battery Cell Connection
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Solution Overview
Problem
The assembly of busbar assemblies to battery cells in electric vehicles is complex, requiring improved methods for easier assembly while ensuring proper electrical connections.
Innovation Solution
A busbar assembly design featuring conductive busbars with spring contacts and insulative members, allowing for easier engagement with battery cell terminals and ensuring secure, non-shorting electrical connections across multiple arrays of battery cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional busbar assemblies are used to connect battery cells, then electrical connections are established, but the assembly process becomes complex and difficult
Solution Approach 1:
The spring contacts are nested within the busbar assembly structure, with each spring contact positioned inside a cavity formed by the busbar and insulative member. This nesting integrates multiple components (busbar, spring contact, insulative member) into a compact unit that simplifies assembly while maintaining reliable electrical connections between battery cells.
2Reliability
If busbar assemblies are designed for secure electrical connections, then reliability is improved, but assembly complexity increases
Solution Approach 1:
The spring contacts are designed to automatically engage with battery cell terminals through their inherent spring force, eliminating the need for additional fastening operations or complex alignment procedures. The spring mechanism self-adjusts to maintain reliable electrical connection, reducing assembly complexity while ensuring connection reliability.
Solution Approach 2:
The busbar, spring contact, and insulative member are combined into an integrated assembly unit. The insulative member is positioned between the spring contact and busbar to prevent shorting while maintaining electrical connection, merging multiple functions (conduction, insulation, mechanical support) into a single integrated component that simplifies the overall assembly process.
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 proposed busbar assembly simplifies the connection process, ensures reliable electrical contacts, and allows for easy disassembly and reuse, addressing the complexity and reliability challenges in existing busbar assembly technologies.
Implementation Method 1
a first spring contact extending therefrom
Data Source
AI summary
A busbar assembly includes a first conductive busbar having an opening therethrough and a first spring contact extending therefrom, a second conductive busbar having a second spring contact extending therefrom, wherein the second spring contact extends through the opening, and an insulative member between the first and second conductive busbars. A plurality of the openings, the first spring contacts and the second spring contacts are provided as part of the assembly.