Vehicle Battery Bus Bar Fixing with Elastic Damping

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Solution Overview

Problem

The existing taping method for fixing high voltage lines in vehicle battery systems is complex, time-consuming, and poses safety risks due to exposure of energized parts during vibrations from external shocks.

Innovation Solution

A battery system design that uses elastic pads and bodies to securely fix bus bars and wire harnesses, with elastic pads featuring fixing grooves and protrusions to prevent separation and exposure, and elastic bodies at ends of bus bars to absorb vibrations, simplifying assembly and enhancing safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the taping method is used to fix the high voltage line, then the assembly process is simple, but the assembly time is long and the safety is compromised due to exposure of energized parts during vibrations

Engineering Contradiction:

Improveassembly process simplicityVSAvoidsafety of energized parts

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The battery system is divided into modular battery modules, each with its own bus bars and wire harnesses. The upper case is segmented into multiple sections that can be assembled independently. This modular approach simplifies assembly while ensuring proper containment and protection of energized parts through structured segmentation of components and spaces.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Elastic pads are introduced as intermediary components between the wire harnesses and the upper case. These elastic pads provide both mechanical support and vibration damping, protecting the energized parts while maintaining simple assembly. The elastic bodies at bus bar ends serve as intermediaries to absorb vibrations and prevent exposure of high voltage lines.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If the taping method is used to fix the high voltage line, then the structure is simple, but the assembly time is long

Engineering Contradiction:

Improvestructural simplicityVSAvoidassembly time

Core Design Contradiction:

Device complexityVSLoss of time

Solution Approach 1:

The wire harnesses are pre-assembled with the battery modules, and the elastic pads are pre-positioned in the upper case sections. The bus bars are pre-equipped with elastic bodies at their ends. These preliminary preparations enable rapid final assembly without time-consuming taping operations, reducing assembly time while maintaining structural simplicity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system incorporates elastic pads and elastic bodies that provide dynamic vibration absorption. These elastic components allow the structure to adapt to vibrations naturally without requiring complex rigid constraints or time-consuming securing operations, thus reducing assembly time while maintaining protection of energized parts.

Inventive Principle:

Principle #15Dynamics

3Quantity of substance

If the taping method is used to fix the high voltage line, then the materials required are minimal, but the protection against vibrations is insufficient

Engineering Contradiction:

Improvematerial quantityVSAvoidvibration exposure of energized parts

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The system changes the physical parameters of the fixation approach by using elastic materials with specific mechanical properties. The elastic pads and elastic bodies are designed with appropriate elasticity and damping characteristics to effectively absorb vibrations while protecting energized parts. This parameter-based approach provides superior vibration protection compared to taping, using minimal material quantity.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The elastic bodies at the bus bar ends convert the harmful vibrations into beneficial elastic deformation and energy absorption. Instead of trying to rigidly constrain the bus bars and wire harnesses, the system allows controlled elastic movement that dissipates vibration energy, protecting the energized parts from damage while using minimal material.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This design simplifies the assembly process, enhances safety by preventing exposure of high voltage lines, and minimizes interference between components during external shocks, improving workability and safety compared to conventional methods.

Implementation Method 1

elastic pads spaced apart along a longitudinal direction of the wire harness to fix the wire harness; and a plurality of elastic bodies respectively disposed at an upper end and a lower end of the bus bars to fix the bus bars

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS20220209351A1Battery system of vehicle

Publication Date: 2022.06.30 HYUNDAI MOBIS CO LTD

AI summary

A battery system of a vehicle includes: a plurality of battery modules each including a battery cell assembly and a bus bar; an upper case spaced apart from an upper portion of the battery modules; a wire harness disposed between the battery modules and the upper case to be connected to the battery modules; elastic pads spaced apart along a longitudinal direction of the wire harness to fix the wire harness; and a plurality of elastic bodies respectively disposed at an upper end and a lower end of the bus bars to fix the bus bars.