Battery Pack Bus Bar Connection With Insulating Spacer Reconnection
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Solution Overview
Problem
Existing battery pack assembly methods require cautious handling to avoid electric shock during reconnection of voltage detection lines and bus bars, posing safety risks during repair.
Innovation Solution
A connection method involving a bus bar housed in an insulating bus bar case with a spacer made of insulating material to ensure close contact and fixation, reducing the risk of electric shock during reconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the voltage detection line is re-connected to the bus bar in an assembled battery pack, then the connection can be restored, but the risk of electric shock increases due to direct exposure of conductive parts
Solution Approach 1:
The patent introduces an insulating spacer as an intermediary component between the voltage detection line and the bus bar. This spacer serves as a mediator that enables the connection process while simultaneously providing electrical insulation to eliminate the electric shock hazard during reconnection operations.
Solution Approach 2:
The insulating spacer is designed to be pre-installed or positioned before the voltage detection line is connected to the bus bar. This prior placement of the insulating component cushions against the harmful electric shock effect before the connection is made, ensuring safety during the repair process.
2Reliability
If the bus bar and voltage detection line are pressed together for secure connection, then connection reliability improves, but the risk of short circuit and electric shock increases
Solution Approach 1:
The insulating spacer acts as a mediator that allows the bus bar and voltage detection line to be pressed together for reliable mechanical and electrical connection while preventing direct conductive contact that would cause short circuits. The spacer is positioned to provide insulation at critical points where pressing occurs.
3Object-affected harmful factors
If insulation measures are added to reduce electric shock risk, then safety improves, but device complexity increases
Solution Approach 1:
The insulation function is segmented into a separate, dedicated component - the insulating spacer - rather than being integrated into the bus bar or voltage detection line themselves. This segmentation allows the insulation function to be added independently without redesigning the entire connection system, thus improving safety with minimal increase in overall complexity.
Solution Approach 2:
The insulating spacer is designed as a simple, inexpensive component that can be easily replaced if needed. This approach allows safety improvements through the addition of a low-cost element rather than complex, expensive insulation systems, minimizing the impact on device complexity and cost.
Data Source
AI summary
To provide a connection method adapted to connect a bus bar and a voltage detection line in such a way that the possibility of electric shock is reduced in the case of performing re-connection in an assembled battery pack. A connection method according to the present disclosure is a connection method for performing connection between the bus bar and the voltage detection line in a battery pack. In this connection method, the voltage detection line is joined to the bus bar housed in a bus bar case made of an insulating material, and a spacer is fixed to the bus bar case under a state in which the bus bar and the voltage detection line are pressed between the bus bar case and the spacer made of an insulating material to thereby bring the bus bar and the detection line in close contact with each other.