Innovative Friction Locking Mechanism for High Voltage Busbar Connections in EV Batteries

In the development of high-voltage (HV) batteries, ensuring secure connections between HV conductors and maintaining the safety and performance of the battery pack is paramount. Therefore, In the pursuit of enhancing efficiency and reliability in electrical connections, this paper explores the innovative alternate for a traditional screwing method with a friction locking mechanism for connecting busbars. The novel design reimagines the busbar as a Friction clamp (Female part) that securely holds the male part of the Busbar, significantly increasing the contact surface area up to 50%. This enhanced surface area not only improves electrical conductivity but also reduces heat generation, addressing common issues associated with traditional screw-based connections. By eliminating the need for screws, the new design streamlines the assembly process, resulting in reduced cycle times and improved overall assembly line efficiency. This study presents the design methodology, performance analysis, and potential applications of the friction locking mechanism, demonstrating its advantages over conventional screwing methods in terms of thermal management, mechanical stability, and production efficiency.Post patent filing and concept approval, an iterative CAD-CAE (Computer-Aided Design and Computer-Aided Engineering) loop was employed to refine and enhance the initial concept. Key takeaways from this process include critical material selection and potential design optimizations aimed at improving performance and manufacturability. The paper concludes with the results of prototype evaluations, rigorously tested against the current validation plan for series components to ensure compliance with required standards. Additionally, a detailed manufacturing feasibility check was conducted to assess the potential for series production implementation. • The contact surface area was increased by 50%. • Enhanced contact surface led to a 10% improvement in electrical conductivity and a reduction in hot spots. • By eliminating conventional fasteners, the overall series production time was reduced by approximately 30 seconds compared to the traditional screw method.