Swaging Structure for Bus Bar Metallic Members
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional swaging structures for connecting metallic members, particularly in bus bars for battery modules, suffer from high electrical resistance and reduced conductivity due to dissimilar metallic materials and poor junction quality, leading to instability and short lifespan in in-vehicle applications.
Innovation Solution
A swaging structure featuring a flat plate-shaped first metallic member with a groove and a disc-shaped second metallic member with a vertical flange, where the flange is deformed to fill the groove, ensuring a close and flat connection, reducing electrical resistance and enhancing conductivity between dissimilar materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional swaging structure is used to connect dissimilar metallic materials, then connection strength is achieved, but electrical resistance increases and conductivity deteriorates
Solution Approach 1:
The invention applies different structural features to different regions: the groove portion is provided only at the circumferential region where contact occurs, while the central hole portion maintains its original structure. This local modification optimizes electrical contact quality without compromising the overall connection strength, thereby resolving the contradiction between mechanical strength and electrical conductivity.
Solution Approach 2:
The groove portion is pre-formed on the metallic plate before the swaging process. When the metallic member is fitted and swaged, the material flow is guided by the groove, ensuring optimal contact and reduced electrical resistance from the outset. This preliminary preparation prevents poor junction quality that would otherwise occur with conventional swaging of dissimilar metals.
2Strength
If pawl portion is deformed to engage with hole portion in conventional swaging, then connection strength is achieved, but junction portion quality deteriorates with concavities and convexities
Solution Approach 1:
The groove portion acts as an intermediary structure between the metallic plate and the fitted metallic member. It guides the material flow during swaging and ensures uniform contact, preventing the formation of concavities and convexities. This intermediary feature maintains junction flatness while still achieving strong mechanical connection.
Solution Approach 2:
The invention changes the geometric parameters of the hole portion by adding the groove feature. This modification alters the material flow characteristics during swaging, transforming the deformation pattern to produce a flat, uniform junction surface instead of the irregular surface produced by conventional swaging.
3Reliability
If multiple bus bars are used to connect battery cells, then electrical connection is achieved, but total electrical resistance increases
Solution Approach 1:
The groove portion ensures uniform material distribution and consistent contact pressure around the entire circumference of the junction. This homogenizes the electrical contact properties, creating a uniformly low-resistance path that reduces total electrical resistance compared to conventional non-uniform joints.
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
The solution provides a stable and firm connection with reduced electrical resistance and improved conductivity, enabling efficient power supply with minimal loss in bus bars connecting multiple batteries, particularly in hybrid and electric vehicles.
Implementation Method 1
when the second metallic member is swaged onto the first metallic member, the vertical flange of the second metallic member is deformed, and the groove portion of the first metallic member is filled with the deformed vertical flange
Data Source
AI summary
A swaging structure for metallic members includes a metallic plate having a hole portion, and a disc-shaped conductive member which is fitted in the hole portion and fixed to the metallic plate by swaging a circumference of the hole portion. The metallic plate includes a groove portion provided in at least one surface side of the metallic plate about the hole portion of the metallic plate, and the conductive member includes a vertical flange provided on an outer circumference of the conductive member and protruding from the at least one surface side. The conductive member is fitted in the hole portion of the metallic plate, and when the conductive member is swaged onto the metallic plate, the vertical flange of the conductive member is deformed, and the groove portion of the metallic plate is filled with the deformed vertical flange.