Battery Pack Bus Bar Fixing Structure for Vibration Resistance
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Solution Overview
Problem
The existing bus bars in battery packs for electric vehicles are prone to cracks and physical damage due to vibrations and external forces, leading to poor assemblability and increased manufacturing costs due to the use of additional components like fixing brackets or clips.
Innovation Solution
A battery pack design featuring a cross beam structure with insulating covers and spacer protrusion pieces that support and stabilize high-current connectors, reducing the need for separate fixing components and enhancing durability and assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate fixing brackets or clips are installed at the bus bar, then the bus bar is protected against vibration and external forces, but the device complexity increases and manufacturing cost increases
Solution Approach 1:
The fixing function is merged into the insulating cover itself. The insulating cover includes positioning protrusions that directly engage with positioning grooves on the bus bar, eliminating the need for separate fixing brackets or clips. This integration reduces component count while maintaining protection against vibration and external forces.
2Reliability
If separate fixing brackets or clips are installed at the bus bar, then the bus bar is protected against vibration and external forces, but the assemblability deteriorates
Solution Approach 1:
The fixing function is merged into the insulating cover itself. The insulating cover includes positioning protrusions that directly engage with positioning grooves on the bus bar, eliminating the need for separate fixing brackets or clips. This integration reduces component count while maintaining protection against vibration and external forces.
3Reliability
If separate fixing brackets or clips are installed at the bus bar, then the bus bar is protected against vibration and external forces, but the manufacturing cost increases
Solution Approach 1:
The fixing function is merged into the insulating cover itself. The insulating cover includes positioning protrusions that directly engage with positioning grooves on the bus bar, eliminating the need for separate fixing brackets or clips. This integration reduces component count while maintaining protection against vibration and external forces.
4Adaptability or versatility
If the bus bar is made longer to connect electronic units, then the electrical connection coverage is improved, but the bus bar becomes more susceptible to vibration and external forces
Solution Approach 1:
The insulating cover acts as an intermediary protective element. It covers the bus bar and includes positioning protrusions that engage with positioning grooves, providing mechanical support and protection. This allows the bus bar to be longer for better electrical connection coverage while the insulating cover protects it from vibration and external forces.
Data Source
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AI summary
A battery pack with an improved fixing structure enabling improved movement restriction and assembly for a high-current bus bar includes battery modules including a first electrical connection between battery cells, a second electrical connection between battery modules, a battery manager configured to control charging and discharging of the battery module, a connector comprising a third electrical connection between an output terminal of the battery module and the battery manager, a cross beam extending between a housing first wall portion and a housing second wall portion, defining an open portion, and including a cross beam bottom opposite to the open portion, and a pair of cross beam sidewalls, and an insulating cover including a base plate covering the open portion and a spacer protrusion piece protruding from the base plate toward the connector to support the connector.