Bolted Busbar Structure for Compact Battery Pack Assembly
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Solution Overview
Problem
Existing busbars in battery packs have complex structures and occupy large spaces, complicating assembly and reducing space utilization.
Innovation Solution
A bolted busbar design comprising a post assembly with a connecting block and plastic wrapper, fasteners, and busbar boards that directly connect to cell terminals without receding structures, allowing for simple installation and reduced space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If receding structures are arranged on busbars to connect support beams, then structural stability is ensured, but the busbar structure becomes complex and occupies large space
Solution Approach 1:
The busbar is divided into separate components: busbar bodies and independent support beam connection structures. The support beam connection structures are detached from the busbar bodies and can be independently installed, simplifying the busbar structure while maintaining the ability to connect support beams for structural stability.
Solution Approach 2:
The support beam connection structures are extracted from the busbar bodies, removing the complex receding structures from the main busbar design. This allows the busbar to have a simple rectangular prism shape while the connection structures provide the necessary support beam integration capability.
2Stability of the object's composition
If receding structures are arranged on busbars to connect support beams, then structural stability is ensured, but assembly process becomes complex
Solution Approach 1:
By segmenting the busbar system into separate busbar bodies and connection structures, the assembly process is simplified. The connection structures with pre-formed support beam interfaces can be independently installed without requiring complex integration with the busbar manufacturing process.
Solution Approach 2:
The support beam connection structures are designed with pre-formed connection interfaces and fastening mechanisms (such as buckles or slots) that enable preliminary preparation of connection points, making the assembly process more straightforward and less complex.
3Adaptability or versatility
If traditional busbars with receding structures are used, then support beam connection is achieved, but space utilization is reduced
Solution Approach 1:
Segmenting the connection functionality into separate detachable structures allows the main busbar to maintain a compact rectangular prism shape with minimal volume, while the connection structures can be added only where needed for support beam integration.
Solution Approach 2:
The connection structures extend from the busbar in directions that optimize space utilization, using the third dimension strategically to provide connection capability without increasing the primary footprint of the busbar assembly.
Data Source
AI summary
Disclosed are a bolted busbar and a battery packing comprising the bolted busbar. The bolted busbar comprises a post assembly, a first busbar board and a second busbar board, wherein the post assembly comprises a connecting block and a plastic wrapper wrapping around the connecting block, the first busbar board and the second busbar board are respectively fixed to two sides of the connecting block, and cell connecting portions are arranged on the first busbar board and the second busbar board and connected to post terminals of cells. The bolted busbar is not provided with a receding structure, thus being simple in structure and easy to install.