Battery Module Housing With Embedded Bus Bar Against Molding Deformation
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Solution Overview
Problem
Existing electric component housings in battery modules suffer from deformation during the cooling process after injection molding, leading to reduced mechanical strength and reliability, and they also have limited space utilization due to the presence of cables or bus bars.
Innovation Solution
The proposed solution involves an electric component housing made of plastic with a metal support structure embedded inside, using insert injection molding. This metal support structure includes a bus bar with terminal portions exposed and a connection portion embedded within the housing, providing mechanical rigidity and acting as a current path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If injection molding is used to manufacture the housing, then manufacturing efficiency and cost are improved, but deformation occurs during cooling leading to reduced dimensional reliability and mechanical strength
Solution Approach 1:
A metal support structure is embedded into the housing during the injection molding process before the housing cools and solidifies. This preliminary reinforcement prevents deformation during the cooling phase and maintains dimensional reliability without compromising manufacturing efficiency
Solution Approach 2:
The housing is constructed as a composite structure combining plastic material with an embedded metal support structure. This composite design provides the benefits of injection molding while adding rigidity and dimensional stability to prevent cooling deformation
2Volume of moving object
If the size of the electric component housing is reduced to accommodate miniaturization trends, then space utilization is improved, but the space for cables and bus bars becomes limited
Solution Approach 1:
The bus bar is integrated directly into the housing structure, merging the electrical connection function with the structural housing. This eliminates the need for separate cable routing spaces and allows for more efficient use of the reduced housing volume
Solution Approach 2:
The bus bar is positioned and configured within the three-dimensional space of the housing in an optimized arrangement that utilizes vertical and lateral dimensions efficiently, maximizing space utilization in the miniaturized housing
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
The integration of the metal support structure enhances the mechanical rigidity and deformation resistance of the housing, while also optimizing space utilization by embedding the bus bar within the housing, thus eliminating the need for external insulation and improving packaging efficiency.
Implementation Method 1
The housing body may be made of a plastic material, and the housing body may be prepared by insert injection molding together with the metal support structure.
Implementation Method 2
the bus bar may include terminal portions having a fastening hole and corresponding to both end portions and a connection portion configured to form a current path between the terminal portions
Data Source
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AI summary
The present disclosure discloses an electric component housing for accommodating electric components. The electric component housing of the present disclosure includes a housing body forming an appearance of the electric component housing; and a metal support structure embedded inside the housing body.