Systems and methods for boltless busbar joints
AssigneeFord Global Technologies, LLC
InventorsJohn Casci, Fan Wang, Baoming Ge
Life of this patent
Estimating the term…
Abstract
Methods and systems are provided for assemblies including two busbars connected via boltless busbar joints, without fasteners. In one example, a method for connecting a first busbar to a second busbar without fasteners includes stamping the second busbar to form two slots separating a middle piece from prongs, bending the middle piece into a clip, and interposing the first busbar between the clip and the prongs. Additionally, contact areas of the first and second busbars are pre-treated with a surface texturing method.
Claims20
A method for connecting a first busbar to a second busbar without fasteners, comprising:
- stamping the second busbar to form two slots separating a middle piece from prongs;
- bending the middle piece into a clip;
- and
- interposing the first busbar between the clip and the prongs, where contact areas of the first and second busbars are pre-treated with a surface texturing method.
An assembly, comprising:
- a first busbar with a prong contact surface and a clip contact surface, the prong contact surface and the clip contact surface facing opposite directions;
- and
- a second busbar having prongs integral with a clip, the clip comprising segments including a first segment bent at a first non-zero angle with the prongs and a second segment bent at a second non-zero angle with the first segment, wherein the first busbar is interposed and compressed between the prongs and the clip with the prong contact surface in face-sharing contact with prong inner surfaces of the prongs and the clip contact surface in face-sharing contact with clip inner surfaces of the clip such that the first busbar and the second busbar are removably, electrically, and mechanically coupled without fasteners.
A vehicle, comprising:
- an energy storage device;
- an inverter configured to condition electrical energy in and out of the energy storage device;
- and
- an electric machine configured to convert the electrical energy to mechanical energy that is delivered to drive wheels, wherein the electric machine is electrically and mechanically coupled to the inverter via a boltless busbar joint, including:
- a first busbar;
- and
- a second busbar including a clip that is bent and two prongs positioned on either side of the clip, wherein the first busbar is wider than the clip such that the first busbar is in face-sharing contact with both of the prongs and the clip, and wherein the clip is under elastic tension that clamps the first busbar between the prongs and the clip, mechanically and electrically coupling the first busbar with the second busbar.
Dependencies are inferred from the claim text.