Bus Bar Insert Molding for Fuse Exchange
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Solution Overview
Problem
Existing energy storage apparatuses face challenges in exchanging fuses while maintaining insulation and simplicity of bus bar structures, leading to complex assemblies and increased resistance due to numerous fastening portions.
Innovation Solution
The energy storage apparatus features a bus bar formed by insert molding within the outer case, allowing for insulation and a simple structure, with an exposed portion for detachable mounting of the circuit breaking part, enabling easy exchange without removing the outer case and ensuring hermeticity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the bus bar has a complicated structure to enable fuse exchange, then the circuit breaking part can be exchanged, but the bus bar structure becomes complex and resistance increases
Solution Approach 1:
The bus bar is divided into an inner exposed portion (inside the outer case) and an outer exposed portion (outside the outer case), with a connection portion linking them. This segmentation allows the circuit breaking part to be mounted on the outer exposed portion for easy exchange, while the inner exposed portion maintains insulation and structural integrity inside the outer case.
Solution Approach 2:
The connection portion acts as an intermediary element that connects the inner exposed portion and the outer exposed portion. This intermediary structure enables the outer exposed portion to extend outside the outer case for fuse exchangeability, while the inner exposed portion remains insulated inside the outer case, thus resolving the contradiction between exchangeability and structural complexity.
2Ease of repair
If the bus bar has a complicated structure with numerous fastening portions, then the circuit breaking part can be exchanged, but assembly complexity increases and resistance increases
Solution Approach 1:
The bus bar is formed as an integral structure where the inner exposed portion, connection portion, and outer exposed portion are combined into a single piece. This merging eliminates the need for multiple separate fastening portions and complex assembly steps, while still providing the outer exposed portion for circuit breaking part exchangeability.
3Reliability
If the bus bar is formed by insert molding in the outer case, then insulation and hermeticity are maintained, but the circuit breaking part cannot be exchanged
Solution Approach 1:
The bus bar is segmented into portions inside and outside the outer case. The inner exposed portion is formed by insert molding inside the outer case to maintain insulation and hermeticity, while the outer exposed portion extends outside the outer case to enable circuit breaking part exchangeability.
Solution Approach 2:
The bus bar structure extends in the spatial dimension from inside to outside the outer case. The inner exposed portion remains in the original dimension (inside the outer case) for insulation, while the outer exposed portion extends to another dimension (outside the outer case) to enable exchangeability without compromising the hermetic seal.
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
This configuration allows for the exchange of circuit breaking parts while maintaining insulation and simplicity, reducing assembly complexity and resistance, and enhancing the rigidity and gas tightness of the apparatus.
Implementation Method 1
a bus bar which connects the electrode terminal or the external connection part with the circuit breaking part, and which is formed in the outer case by insert molding
Data Source
AI summary
An energy storage apparatus includes: an energy storage device which includes an electrode terminal; an outer case; and an external connection terminal. The external connection terminal includes: an external connection part to be connected to an external conductive member; a circuit breaking part; and a bus bar which connects the electrode terminal or the external connection part with the circuit breaking part, and which is formed in the outer case by insert molding. The bus bar includes an outer exposed portion on which the circuit breaking part is detachably mounted from the outside of the outer case.