Battery Pack Terminal Block Structure for Stable Bolt Connections
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Solution Overview
Problem
Existing battery packs face issues with unstable electrical connections and damage to terminal blocks due to high fastening torque, leading to loose connections and reduced durability.
Innovation Solution
A battery pack design featuring a press-in nut with a protruding portion bonded to the terminal block, offsetting the downward pressure from the terminal bolt during fastening, and using different metals for the terminal bolt and block to enhance durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a terminal block made of soft material or metal with low mechanical rigidity is used to receive large current, then electrical resistance is reduced, but the terminal block is damaged by fastening torque of the fastening bolt
Solution Approach 1:
The terminal block is divided into two separate components: a soft terminal block for electrical connection and a hard fastening structure for mechanical support. This segmentation allows each component to be optimized for its specific function without compromise.
Solution Approach 2:
A separate fastening structure acts as an intermediary between the terminal block and the bolt. This intermediary absorbs the mechanical stress and fastening torque, protecting the soft terminal block from damage while maintaining electrical connection stability.
2Strength
If a fastening bolt with low fastening torque is used to prevent terminal block damage, then terminal block durability is improved, but the fastening bolt may be loosened by vibration or mechanical shock
Solution Approach 1:
The fastening function is separated from the terminal block by introducing a dedicated fastening structure. This allows the bolt to apply high torque to the fastening structure without damaging the terminal block, while the electrical connection remains protected.
Solution Approach 2:
The fastening structure serves as a mediator that absorbs mechanical stresses including vibration and shock. It protects the electrical connection from loosening while allowing the bolt to maintain secure fastening through the fastening structure alone.
3Reliability
If high fastening torque is applied to secure the terminal bolt, then connection stability is improved, but the terminal block is damaged
Solution Approach 1:
The fastening structure acts as an intermediary component between the terminal bolt and the terminal block. It absorbs the high fastening torque and mechanical stresses, protecting the terminal block from damage while maintaining secure connection stability.
Solution Approach 2:
The fastening function is extracted from the terminal block and placed into a separate fastening structure. This allows high fastening torque to be applied to the fastening structure without transferring damaging forces to the terminal block.
Data Source
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AI summary
Disclosed is a battery pack that maintains a stable electrical connection and enhances the durability of interconnected parts. The battery pack includes a cell module having at least one battery cell; and a BMS module including a BMS board configured to control charging and discharging of the cell module, a terminal block loaded on the BMS board and configured such that a connection terminal is placed thereon and to have a connection hole into which a bolt is inserted, a terminal bolt configured to be inserted into the connection hole, and a press-in nut having a body portion with a bolt hole into which a body of the terminal bolt is inserted, the bolt hole having a thread formed at an inner surface thereof, and a protruding portion configured to protrude outward from an outer circumference of the bolt hole and bonded to an outer circumference of the connection hole of the terminal block.