Battery Pack Bus Bar Fixing Structure
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Solution Overview
Problem
Existing battery packs for electric vehicles face instability in bus bar connections due to vibrations, leading to potential electrical disconnection or damage, which can result in accidents such as fires, especially when bus bars need to be extended between distant modules.
Innovation Solution
A battery pack design that includes a base with a module fixing part and bus bar fixing parts, where the bus bar is securely fixed using a combination of bolt coupling and hook coupling mechanisms, with a rotatable second bus bar fixing part to cover and stabilize the bus bar, preventing movement and damage from vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the bus bar is extended long to connect distant battery modules, then the connection distance is increased, but the bus bar becomes readily shaken and unstable
Solution Approach 1:
The bus bar fixing structure is divided into multiple segments: a first bus bar fixing part that provides initial support and a second bus bar fixing part that provides additional stabilization. This segmentation allows the long bus bar to be supported at multiple points along its length, reducing vibration and instability while maintaining the necessary connection distance between distant battery modules.
2Length of stationary object
If the bus bar is extended long to connect distant battery modules, then the connection distance is increased, but the risk of electrical disconnection and damage increases
Solution Approach 1:
The dual-component fixing structure segments the support function, with the first fixing part providing primary attachment and the second fixing part providing additional constraint. This segmentation ensures that even if one fixing mechanism is subjected to stress, the other maintains the electrical connection, thereby enhancing reliability for long-distance bus bar connections.
Solution Approach 2:
The second bus bar fixing part acts as a pre-positioned protective element that cushions against potential vibrations and impacts before they can cause electrical disconnection or damage. By having this additional fixing mechanism in place beforehand, the system preemptively protects the electrical connection reliability.
3Device complexity
If a simple fixing method is used for the bus bar, then the device complexity is reduced, but the fixation stability is insufficient
Solution Approach 1:
The fixing structure is segmented into two distinct parts with different functions: the first bus bar fixing part for basic attachment and the second bus bar fixing part for enhanced stabilization. This segmentation provides the necessary stability without requiring an overly complex single-component solution, as each segment performs its specific function efficiently.
Data Source
AI summary
An embodiment of the present invention relates to a coupling structure of a battery pack, and the objective of the present invention is to provide a battery pack which can stably and easily fix a bus bar. To this end, provided is a battery pack comprising: a base defining the entire bottom surface; a battery module installed on the base; a module fixing part positioned around a side surface and an upper surface of the battery module and coupled to the base; a first bus bar fixing part coupled to the module fixing part; a bus bar disposed on the first bus bar fixing part and electrically connectable to the battery module; and a second bus bar fixing part installed to cover the bus bar and fixed to the first bus bar fixing part.