Battery Pack Connection Module for Internal Bus Bar Assembly
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Solution Overview
Problem
The manufacturing process of battery packs is complicated by the need to separately perform connector connection after sealing the gap between the upper and lower cases, as existing configurations require external output connectors on the upper case.
Innovation Solution
A connection module is designed to be accommodated inside the casing, comprising bus bars, holders, and a bracket that allow electrical connection between devices on the upper and lower cases, with clearances set between bus bars and holders to accommodate positional shifts and dimensional variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the connector for external output is provided on the upper case side, then the device can be electrically connected to external output, but the manufacturing process becomes complicated because connector connection must be performed separately after sealing the gap between upper and lower cases
Solution Approach 1:
The connection module is divided into separate components: bus bars for electrical connection, holders for positioning, and a bracket for support. This segmentation allows the electrical connection to be completed independently within the lower case before sealing, eliminating the need for post-sealing connector installation and simplifying the manufacturing process
Solution Approach 2:
The bracket acts as an intermediary structure that holds the holders and bus bars in place within the lower case. This intermediary framework enables the electrical connection components to be securely positioned and connected before the upper and lower cases are sealed together, resolving the conflict between connection reliability and manufacturing simplicity
2Adaptability or versatility
If clearances are set between bus bars and holders, then positional shifts and dimensional variations can be accommodated, but the precision of electrical connection may be affected
Solution Approach 1:
The design incorporates clearances as a parameter change that allows the bus bars to accommodate positional shifts and dimensional variations. The holders are designed with specific clearance dimensions that enable the bus bars to move within acceptable ranges while maintaining reliable electrical connection, thus adapting to manufacturing tolerances without compromising connection precision
Data Source
AI summary
A connection module is configured to be accommodated inside a battery pack including an upper case and a lower case, the connection module including: a plurality of bus bars that electrically connect a device disposed on the upper case side inside the battery pack to a connector disposed on the lower case side inside the battery pack; a plurality of holders that hold the plurality of bus bars, each of the plurality of holders including bus bar holding portions; and a bracket capable of locking the plurality of holders, wherein, in a state in which the plurality of holders that hold the plurality of bus bars are locked to the bracket, the plurality of bus bars are arranged side by side in a left-right direction orthogonal to a vertical direction, a direction orthogonal to the vertical direction and intersecting the left-right direction is assumed to be a front-rear direction.