Stacked Busbar Connector Layout for Shield-Free EV High-Voltage Links
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Solution Overview
Problem
Traditional high-voltage connecting mechanisms for electric vehicles have complex structures, high costs, and cause electromagnetic interference, necessitating additional shielding layers that increase weight and cost.
Innovation Solution
A connecting mechanism with stacked busbars and integrated insulation, eliminating the need for external shielding by reducing electromagnetic interference through proper spacing and material selection, and incorporating a memory alloy clip for secure connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a high-voltage battery is disposed of in a vehicle cradle, then the battery can be integrated into the vehicle structure, but the battery is exposed to salt water spray and road debris causing corrosion
Solution Approach 1:
The battery cover serves multiple functions: it seals the battery compartment, provides corrosion protection through coating, and integrates with the vehicle's aesthetic design as an exterior panel. This multi-functionality resolves the contradiction by maintaining battery integration benefits while adding protective capabilities.
Solution Approach 2:
A corrosion-resistant coating is applied between the battery cover and the corrosive environment (salt water spray and road debris). This intermediary layer protects the underlying metal structures from direct exposure to harmful factors while allowing the battery to remain integrated in the vehicle cradle.
2Strength
If the battery cover is made from metal, then the cover provides structural strength, but the metal is susceptible to corrosion from salt water spray and road debris
Solution Approach 1:
The battery cover assembly combines metal structural components with a corrosion-resistant coating layer. This composite structure maintains the structural strength benefits of metal while protecting against corrosion through the coating, resolving the contradiction between strength and corrosion resistance.
Solution Approach 2:
A protective coating is applied to the metal battery cover surfaces that are exposed to the environment. This intermediary layer maintains the metal's structural strength while preventing direct contact between the metal and corrosive elements like salt water spray and road debris.
3Object-affected harmful factors
If the battery cover is made from plastic, then the cover is resistant to corrosion, but the cover lacks structural strength and stiffness
Solution Approach 1:
The battery cover system uses a composite approach combining plastic components (for corrosion resistance) with metal reinforcement elements or coated metal structures (for strength). This resolves the contradiction by integrating materials that individually address only one aspect of the requirement.
4Ease of operation
If the battery cover is designed to be removable, then the cover allows easy battery access for maintenance, but the cover design becomes more complex
Solution Approach 1:
The battery cover is designed as a separable component that can be removed from the vehicle body. This segmentation allows independent access to the battery while maintaining the overall integrated design. The cover becomes a distinct module that can be easily detached and reattached, providing maintenance access without requiring complex internal mechanisms.
Data Source
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AI summary
A connecting mechanism, an electrical energy transmission device and a motor vehicle are provided by the present disclosure, in which the connecting mechanism includes a male-end connecting mechanism and a female-end connecting mechanism, in which the male-end connecting mechanism includes a busbar, a flat terminal and a male-end shell connected to the busbar and the flat terminal; the female-end connecting mechanism includes a plug-in terminal and a female-end shell connected to the plug-in terminal; the male-end connecting mechanism is electrically connected to the plug-in terminal in the female-end connecting mechanism through the flat terminal, and the male-end shell is connected to the female-end shell to form the connecting mechanism. The busbars are stacked at a proper interval to effectively reduce the electromagnetic interference to other parts after the busbars are energized, thereby achieving the goal of canceling a shielding layer structure of high-voltage charging harnesses and reducing the cost and weight.