Bent Bus Bar Structure for Battery Pack Vibration Protection
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Solution Overview
Problem
Battery packs with cylindrical cells face defects and capacity/output reduction due to damage from high-frequency vibrations, particularly in electric two-wheeled vehicles, where welding areas are prone to damage during use.
Innovation Solution
A bus bar with a terminal fastening unit featuring bent fastening legs that absorb vibration impact by distributing force through inclined and notched structures, reducing the transmission of stress to the welding area and enhancing electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to electrically connect the bus bar to electrode terminals, then electrical connection is achieved, but the welding area becomes vulnerable to damage from high-frequency vibrations
Solution Approach 1:
The bus bar incorporates a bending structure with reduced rigidity in specific regions before vibration damage can occur. This pre-designed flexible section acts as a cushion that absorbs vibration energy, protecting the welding area from harmful stresses during high-frequency vibrations in electric two-wheeled vehicles
Solution Approach 2:
The bus bar features non-uniform rigidity distribution with specific reduced-rigidity sections located away from the welding area. These localized flexible regions are strategically positioned to absorb vibrations while maintaining structural integrity at the critical welding joints, creating different mechanical properties in different parts of the same component
2Strength
If the bus bar structure is made more rigid to maintain structural integrity, then structural strength is improved, but the transmission of vibration impact to the welding area increases
Solution Approach 1:
The bus bar employs differential rigidity design where most of the structure maintains high strength and rigidity for structural integrity, while specific localized sections have reduced rigidity to serve as vibration absorption zones. This creates a gradient of mechanical properties that balances overall strength with localized vibration protection
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The improved bus bar structure minimizes the impact of vibrations on the welding area, ensuring reliable electrical connections and maintaining battery pack performance even under dynamic conditions.
Implementation Method 1
a bending structure capable of absorbing vibration is applied
Data Source
AI summary
A battery pack includes a plurality of battery cells; a pack housing configured to accommodate the plurality of battery cells; and a bus bar having a terminal fastening unit coupled to an electrode terminal of each of the plurality of battery cells and disposed at least one side of the pack housing. The terminal fastening unit has a shape bent toward the electrode terminal from a circumference of a bus bar hole disposed in the bus bar and includes at least one fastening leg coupled to the electrode terminal.