Asymmetric Busbar Design for Electric Storage Device Mounting
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Solution Overview
Problem
Existing electric storage devices for vehicles face challenges in efficient electrical connection and mounting, particularly in preventing incorrect assembly and reducing the risk of short-circuiting during collisions, while also aiming to minimize costs and component types.
Innovation Solution
The electric storage device comprises multiple storage modules with distinct busbars of different lengths, where the long and short storage-module busbars are strategically positioned to prevent incorrect assembly and are mounted on a vehicle such that the short busbars face the front, reducing the risk of short-circuiting during rear collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If storage modules are arranged next to each other with terminals facing each other, then electrical connection is simplified, but the risk of short-circuiting during collision increases
Solution Approach 1:
The patent applies asymmetry by using busbars of different lengths (long busbar and short busbar) to create an asymmetric configuration. The long busbar connects terminals that face each other, while the short busbar connects terminals that do not face each other. This asymmetric design allows the electric storage device to be mounted with the short busbar facing the front of the vehicle, reducing the risk of short-circuiting during rear collisions while maintaining simplified electrical connections between storage modules.
2Reliability
If multiple types of busbars are used to prevent incorrect assembly, then assembly correctness is improved, but device complexity and cost increase
Solution Approach 1:
The patent uses asymmetry by implementing only two types of busbars (long and short) instead of multiple types. The different lengths create an asymmetric configuration that prevents incorrect assembly - the long busbar must connect specific terminals and the short busbar must connect other specific terminals. This asymmetric design achieves reliable assembly correctness while minimizing the number of component types to just two, rather than using multiple different busbar types.
3Object-affected harmful factors
If the electric storage device is mounted with short busbars facing the front, then protection against rear collision damage is improved, but mounting flexibility is reduced
Solution Approach 1:
The asymmetric configuration of long and short busbars creates a unique mounting orientation where the short busbar must face the front of the vehicle. This asymmetric design provides protection against rear collision damage to the terminals connected by the long busbar, while the asymmetry itself serves as a mechanical guide to ensure correct mounting orientation, thereby maintaining mounting flexibility through design guidance rather than reducing it.
Data Source
AI summary
An electric storage device includes at least first to third storage modules and storage-module busbars. The at least first to third storage modules each include a plurality of storage cells. The at least first to third storage modules are arranged next to each other. Storage-module terminals of the at least first to third storage modules are adjacent to each other. The storage-module terminals of the at least first to third storage modules are electrically connected to each other with the storage-module busbars. The storage-module busbars includes a long storage-module busbar and a short storage-module busbar. The long storage-module busbar is provided at a first side of the at least first to third storage modules. The short storage-module busbar is provided at a second side of the at least first to third storage modules. The long storage-module busbar is longer than the short storage-module busbar.