Bus Bar Protrusion Geometry for Smooth Insert Mold Release
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Solution Overview
Problem
The manufacturability of energy storage apparatuses, particularly in integrating bus bars and holders, is a challenge due to the complexity and potential damage during the molding process.
Innovation Solution
The design incorporates a bus bar with a protrusion that protrudes from a holder, featuring a facing surface with a widening interval towards a predetermined direction, allowing for smooth mold removal during insert molding, thereby enhancing manufacturability and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bus bar is integrated with the holder by insert molding, then the joining property between bus bar and holder is improved, but the mold is prone to damage during the molding process
Solution Approach 1:
The bus bar is segmented into multiple portions: a first portion embedded in the holder, a second portion protruding from the holder, and a third portion extending from the second portion. This segmentation allows the mold to only contact the first portion during insert molding, reducing mold damage while maintaining joining property.
Solution Approach 2:
The protruding second portion and extending third portion are extracted from the molded structure, allowing the mold to be removed easily without contacting these portions. This extraction reduces mold damage during the molding process while preserving the electrical connection function.
2Ease of manufacture
If the bus bar structure is simplified for easier manufacturing, then the manufacturability is improved, but the joining property between bus bar and conductor may deteriorate
Solution Approach 1:
The bus bar is divided into functional segments: the first portion for embedding in the holder, the second portion for protruding connection, and the third portion for conductor joining. This segmentation simplifies the manufacturing process while ensuring proper joining properties through dedicated connection portions.
Solution Approach 2:
Different portions of the bus bar have different local qualities optimized for specific functions: the first portion is optimized for molding integration, the second portion for structural support, and the third portion for electrical connection. This local optimization maintains joining property while improving overall manufacturability.
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 design reduces mold damage and improves the joining property between the bus bar and conductor, resulting in enhanced manufacturability and reliability of the energy storage apparatus.
Implementation Method 1
integrating the portion of the bus bar and the holder by insert molding
Data Source
AI summary
An energy storage apparatus includes an energy storage device, a bus bar that is electrically connected to the energy storage device, a holder to hold the bus bar in a state where a portion of the bus bar is fixed, and a conductor that is joined to the bus bar, in which the bus bar includes a protrusion that protrudes with such a posture that the bus bar faces one surface of the holder and is joined to the conductor, the protrusion includes a facing surface that faces the one surface, and an interval between the one surface and the facing surface widens toward a predetermined direction.