The present disclosure is directed towards an electrical busbar for conducting current, and more particularly towards an electrical busbar having alignment features.

INTRODUCTION

Electrical busbars are used to provide a path for current among components. For example, battery systems use busbars to connect cells in parallel and/or series, couple cells to components such as switches, connectors, or fuses. Two or more busbars can be connected together to further extend the current path. It would be advantageous to provide for alignment of busbars to prevent a change in relative position, relative orientation, or both.

Busbar alignment can be achieved with an assembly aid (e.g., a jig) that constrains one or both of the busbars so they cannot move relatively to each other while being secured. However, the additional cost and mass (e.g., if it is a permanent part of the assembly) might not be acceptable.

SUMMARY

The present disclosure is direct to a busbar system. The busbar system includes a first busbar and a second busbar. The first busbar includes a first surface and at least one boss feature extending from the first surface. The second busbar includes a second surface that is configured to contact the first surface and at least one recess feature in the second surface. The at least one boss feature is configured to engage with the at least one recess feature to limit motion of the first busbar relative to the second busbar. For example, each of the first busbar and the second busbar are configured to carry electrical current and allow electrical current to flow from either busbar to the other busbar.

In some embodiments, the at least one boss feature includes a pin. For example, in some embodiments, the pin includes a cylindrical pin, a pin having a circular cross section, a pin having a diamond-shaped cross section, a pin having any other suitable cross section, or any combination thereof. In some embodiments, the at least one boss feature includes a friction drilled feature. In some embodiments, the at least one boss feature includes a pressed feature.

In some embodiments, the at least one recess feature includes a hole. For example, in some embodiments, the at least one recess feature includes a circular hole, a non-circular hole, any other suitably shaped hole, or any combination thereof. In some embodiments, the at least one recess feature includes a slot. For example, in some embodiments, the at least one recess feature includes a rectangular slot, a slot with rounded ends, a curved slot, any other suitably shaped slot, or any combination thereof. In some embodiments, the at least one recess feature includes a punched feature, a pressed feature, or both.

In some embodiments, the first busbar includes a first through-hole, the second busbar further includes a second through-hole, and when the at least one boss feature is engaged with the at least one recess feature, the first through-hole is aligned with the second through-hole. For example, in some embodiments, a fastener is configured to extend though the aligned first through-hole and second through-hole and apply a clamping force to press the first busbar and the second busbar together.

In some embodiments, the at least one boss feature includes more than one boss feature. For example, in some embodiments, the at least one boss feature includes two boss features. In a further example, the two boss features may have substantially the same shape. In a further example, the two boss features may have substantially different shapes. In some embodiments, the at least one recess feature includes more than one recess feature. For example, in some embodiments, the at least one recess feature includes two recess features. In a further example, the two recess features may have substantially the same shape. In a further example, the two recess features may have substantially different shapes.

In some embodiments, the first busbar includes at least one second recess feature in the first surface, the second busbar includes at least one second boss feature in the second surface, and the at least one second boss feature is configured to engage with the at least one second recess feature to prevent motion of the first busbar relative to the second busbar.

In some embodiments, the present disclosure is directed to a method for assembling a busbar system. The method includes positioning a first busbar and a second busbar. The first busbar includes a first surface and at least one boss feature on the first surface. The second busbar includes a second surface and at least one recess feature on the second surface. The method also includes engaging the at least one boss feature with the at least one recess feature to prevent relative motion of the first busbar and the second busbar. In some embodiments, the method includes pressing the first busbar and the second busbar together so that the first surface and the second surface are in contact with each other.

In some embodiments, the first surface and the second surface are in contact with each other at an interface, and the method includes affixing the first busbar to the second busbar. Affixing is achieved by welding the interface, brazing the interface, soldering the interface, pressing the interface, fastening the interface, crimping the interface, deforming the interface, or a combination thereof.

