Battery Pack Mold Assembly for Vibration-Stable Bus Bar Fixing
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Solution Overview
Problem
Existing battery pack structures for electric automobiles are prone to part destruction due to vibrations, which can loosen the fixing state between bus bars and battery module terminals, leading to defective packs and potential damage to electrode leads and inner electrode assemblies.
Innovation Solution
A battery pack structure that incorporates a mold assembly with a main mold and a roof mold, both made of polymer resin with excellent impact resistance, which securely holds the battery modules and bus bars, reducing relative movements and potential damage from vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery modules are fixed using traditional methods (bottom surface fixation or bolt fastening), then the battery pack structure is simple, but the fixing state loosens under vibration impact causing part destruction
Solution Approach 1:
The patent merges the battery module housing with the mold assembly into a single integrated structure. The mold assembly serves dual functions as both the housing structure and the mounting platform for battery modules, eliminating the need for separate fixation mechanisms and reducing structural complexity while improving reliability under vibration
Solution Approach 2:
The mold assembly is constructed using composite materials that provide both structural strength and vibration damping properties. This allows the single component to withstand vibration impacts while maintaining the integrity of battery module connections without requiring additional complex fixation systems
2Reliability
If battery modules are securely fixed to prevent vibration damage, then reliability improves, but the structure becomes more complex
Solution Approach 1:
The mold assembly is designed as a multi-functional component that simultaneously serves as the battery pack housing, the mounting structure for battery modules, and the vibration resistance mechanism. This universal design achieves reliable vibration resistance without adding separate components, thus avoiding increased structural complexity
3Ease of manufacture
If traditional fixation methods are used, then manufacturing is simple, but bus bar connections loosen under vibration causing defects
Solution Approach 1:
The bus bar connections are integrated into the mold assembly structure itself, with bus bars mounted directly to the mold assembly rather than to separate fixtures. This merging of connection structures ensures stable bus bar connections under vibration while maintaining manufacturing simplicity through the single-component design
Data Source
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AI summary
A battery pack is provided. The battery pack includes: a plurality of battery modules mutually connected by a bus bar; a mold assembly including a module receiver configured to receive the battery module; and a pack case configured to receive the mold assembly.