Battery Pack Terminal Structure With Integrated Nut Fastening
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery packs require additional bolts or nuts for terminal fixation, leading to complex structures and increased costs, and bonding methods require separate curing times and shape-dependent sealing members, necessitating additional space for fastening.
Innovation Solution
A battery pack design that eliminates the need for additional bolts or nuts by using a nut-shaped fastening part on the terminal, which is fastened with an internal bolt, allowing for efficient space utilization and simplified assembly, featuring a busbar with a through hole and an internal bolt with a body part and extension part for secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional bolts or nuts are used for terminal fixation, then the terminal can be securely fastened, but the structure becomes complex and cost increases
Solution Approach 1:
The patent merges the terminal body and the fastening component into a single integrated structure. The terminal includes an integrated nut portion that directly receives the bolt, eliminating the need for separate fastening components. This integration reduces structural complexity while maintaining secure terminal fixation.
2Reliability
If additional bolts or nuts are used for terminal fixation, then the terminal can be securely fastened, but the cost increases
Solution Approach 1:
The terminal is manufactured as a single integrated component that includes both the electrical connection portion and the fastening nut portion. This reduces the number of parts that need to be procured, stored, and assembled, thereby lowering manufacturing costs while ensuring reliable terminal fixation.
3Device complexity
If bonding method is used for terminal coupling, then additional fastening components are eliminated, but separate curing time is required and sealing members vary depending on shape
Solution Approach 1:
The patent replaces the chemical bonding process with a mechanical fastening system. The integrated nut portion of the terminal mechanically engages with the bolt, providing immediate structural integrity without requiring curing time. This mechanical solution maintains simplicity while eliminating the time penalty associated with bonding.
4Device complexity
If bonding method is used for terminal coupling, then additional fastening components are eliminated, but sealing members vary depending on shape
Solution Approach 1:
The terminal integrates the sealing function into its structured design. The terminal body and nut portion are designed with built-in sealing surfaces and configurations that provide consistent sealing performance across different applications, eliminating the need for shape-dependent sealing member selection.
5Reliability
If conventional terminal fastening methods are used, then secure connection is achieved, but additional inner space is required for fastening components
Solution Approach 1:
The terminal integrates the fastening function into its body structure, with the nut portion being part of the terminal itself rather than a separate component. This integration eliminates the need for additional inner space dedicated to accommodating separate fastening components, while still providing secure mechanical connection through the bolt-nut interface.
Data Source
AI summary
A battery pack includes a battery module having electrode terminals; a battery module frame accommodating the battery module; an upper housing including at least one through opening and covering an upper portion of the battery module frame; a busbar positioned at an upper portion of the battery module frame and connected to the electrode leads of the battery module; an internal bolt positioned at an upper portion of the battery module frame, protruding upward through the through opening and connected to the busbar; and a terminal passing through the through opening to be connected to the busbar and the internal bolt, wherein the terminal includes a nut-shaped fastening part which is fastened with the internal bolt.