Battery Disconnect Assembly With Embedded Busbar Relay Wiring
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Solution Overview
Problem
Conventional battery disconnect units (BDUs) with multiple relays suffer from deteriorated assemblability and workability due to excessive components and complex electrical connections, leading to increased costs.
Innovation Solution
A battery disconnect apparatus with a lower case and upper case design that includes open upper portions for mounting relays and a circuit board, utilizing an embedded busbar to simplify electrical connections between relays and the circuit board, reducing the need for separate fixing members and cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple relays are mounted in a separate case with individual fixing components, then each relay can be individually accommodated and fixed, but the number of components increases and assemblability deteriorates
Solution Approach 1:
The patent merges multiple relay mounting functions into a single integrated circuit board. The circuit board simultaneously provides mounting support, electrical connection, and structural integration for multiple relays, eliminating the need for separate fixing components for each relay while maintaining reliable mounting stability.
2Reliability
If separate cables and wiring harnesses are used to electrically connect relay coil terminals to connectors, then electrical connections can be established, but the complexity of electrical connection operations increases
Solution Approach 1:
The circuit board integrates both the mounting function and electrical connection function into a single component. The coil terminals of relays are directly connected to the circuit board, eliminating the need for separate cables and wiring harnesses, thereby simplifying assembly while maintaining electrical connection reliability.
3Adaptability or versatility
If multiple separate components are used for relay mounting and electrical connection, then individual relay functionality is ensured, but workability and price competitiveness deteriorate
Solution Approach 1:
The circuit board serves multiple functions simultaneously: it mounts multiple relays, provides electrical connections for all relays, and integrates the overall structure. This multi-functionality reduces the total number of components and assembly steps while preserving individual relay functionality, thereby improving assembly productivity and price competitiveness.
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
Simplifies assembly, improves work productivity, ensures electrical connection stability, and reduces obstruction of air flow, thereby enhancing product reliability and minimizing temperature-related issues.
Implementation Method 1
an embedded busbar embedded in the upper case to be able to electrically connect the fixed contactor of the relay arranged in the mounting space and the circuit board mounted in the receiving space
Data Source
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AI summary
A battery disconnect apparatus is disclosed. The battery disconnect apparatus according to an aspect of the present invention may include: a lower case including a mounting space formed to have an open upper portion and a receiving space formed to have an open upper portion; a relay including a fixed contactor which is mounted in the mounting space through the open upper portion of the mounting space and provided to be exposed to the outside while protruding upward from a body at a predetermined height; a circuit board mounted in the receiving space through the open upper portion of the receiving space; an upper case coupled to the lower case to cover the open upper portion of the mounting space and including an upper mounting space formed at a position corresponding to the mounting space; and a buried bus bar buried in the upper case to electrically connect the fixed contactor of the relay disposed in the upper mounting space and the circuit board mounted in the receiving space in a state in which the upper case and the lower case are coupled to each other.