Battery Pack Adapter Structure for Insulated Bent-Pole Connection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge of connecting the output pole of a battery cell to a power distribution box is complicated due to their height difference and the need for protection, making wire harness routing inconvenient.
Innovation Solution
An adapter structure comprising first and second adapters with bending structures and an insulating bracket, allowing electrical connection while maintaining insulation and reducing space occupation, facilitating easy connection between the output poles and the power distribution box.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the output pole is protected by a protective cover, then the output pole is protected from foreign objects causing short circuit, but the wire harnesses connecting the power distribution box and the output pole become difficult to route
Solution Approach 1:
The protective cover is divided into a cover body and a separate cover plate that can be independently opened. The cover plate is detachably connected to the cover body, allowing it to be opened for wire harness routing and then closed to provide protection, thus segmenting the protective function from the routing function.
Solution Approach 2:
A wire harness guide groove is introduced as an intermediary structure within the protective cover. This groove provides a designated path for wire harnesses to pass through the protective cover, mediating between the need for protection and the need for easy wire routing.
2Device complexity
If the output pole is positioned lower than the power distribution box, then the structural layout is simplified, but the wire harnesses connecting them become difficult to route
Solution Approach 1:
The wire harness routing problem is solved by utilizing the vertical dimension through the protective cover structure. The guide groove allows wires to route vertically through the protective cover, transforming a potentially complex horizontal routing problem into a simpler vertical passage through the cover structure.
3Reliability
If adapters are used to connect the output pole and power distribution box, then electrical connection is achieved, but space is occupied in the battery pack
Solution Approach 1:
The adapter structure is merged with the protective cover assembly. The adapter is integrated into the cover structure such that the protective cover, adapter, and insulation bracket form a unified assembly, reducing the need for separate components and minimizing space occupation in the battery pack.
Solution Approach 2:
The insulation bracket is nested within the adapter structure, with the bending structure passing through the bracket. This nesting arrangement allows multiple functional elements (insulation, adaptation, protection) to occupy overlapping or integrated spaces, reducing the total volume required.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An adapter structure, a battery pack and a vehicle. The adapter structure is applied to the battery pack, and comprises a first adapter, a second adapter and an insulating bracket, wherein the first adapter comprises a first bending structure, which is electrically connected between a first output pole of a battery cell assembly and a power distribution box; the second adapter is spaced apart from the first adapter; the second adapter comprises a second bending structure, which is electrically connected between a second output pole of the battery cell assembly and the power distribution box; and the first bending structure and the second bending structure can pass through the insulating bracket, such that the first adapter and the second adapter are insulated from each other.