Busbar connection systems and methods

A method of securely connecting two or more busbars, the method comprising:

• obtaining a first busbar formed of a first material;
• obtaining a second busbar formed of a second material;
• obtaining a plate member formed of a third material having a higher tensile strength than the first and second materials and defining first and second apertures;
• forming first and second apertures through each of the first and second busbars;
• aligning the first apertures of the first and second busbars and the plate member and securely inserting a first stud member therethrough;
• and
• aligning the second apertures of the first and second busbars and the plate member and securely inserting a second stud member therethrough,
• wherein the first and second stud members mitigate rotational movement between the first and second busbars when connected.

A busbar assembly for an electrified vehicle, the busbar assembly comprising:

• a first busbar formed of a first material and defining first and second apertures;
• a second busbar formed of a second material and defining third and fourth apertures that correspond to the first and second apertures, respectively;
• and
• a connection system comprising:
• a plate member formed of a third material having a higher tensile strength than the first and second materials and defining fifth and sixth apertures,
• a first stud member securely inserted through the fifth aperture of the plate member and the first and third apertures of the first and second busbars, respectively, and
• a second stud member securely inserted through the sixth aperture of the plate member and the second and fourth apertures of the first and second busbars, respectively,
• wherein the connection system mitigates rotational movement between the first and second busbars when connected.