Battery Pack Bus Bar Attachment for Easier Terminal Alignment
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Solution Overview
Problem
In battery packs, handling the bus bar connected to an external device is cumbersome due to lack of efficient design for easy attachment and alignment with the terminal.
Innovation Solution
A battery pack design featuring a bus bar with a protrusion extending laterally and a holding member with an attachment portion and gap, allowing easy attachment and alignment with the terminal, facilitating easier handling and positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional bus bar design is used without special attachment features, then the structure is simple, but the bus bar is difficult to handle and align with the terminal
Solution Approach 1:
The bus bar is segmented into functional zones: a connection portion for electrical connection, an elongated body portion for structural integrity, and a protrusion for attachment. This segmentation allows each part to serve its specific function optimally while maintaining overall simplicity.
Solution Approach 2:
The protrusion acts as an intermediary element between the bus bar and the holding member. It provides a dedicated attachment interface that simplifies the connection process without requiring complex fastening mechanisms, thus improving handling ease while maintaining structural simplicity.
2Manufacturing precision
If a conventional bus bar without protrusion is used, then the manufacturing process is simple, but the alignment with terminal is imprecise
Solution Approach 1:
The protrusion is pre-formed on the bus bar during manufacturing, establishing the attachment geometry in advance. This preliminary action ensures that during assembly, the bus bar automatically aligns with the terminal through the protrusion fitting into the holding member, achieving precise alignment without complex adjustment procedures.
Solution Approach 2:
The protrusion introduces an asymmetric feature on the otherwise symmetric bus bar structure. This asymmetry provides a unique orientation and positioning reference that ensures precise alignment with the corresponding asymmetric receptacle on the holding member, eliminating alignment errors during assembly.
3Reliability
If the bus bar is attached directly to the terminal without a holding member, then the structure is simpler, but the bus bar cannot be securely held and positioned
Solution Approach 1:
The holding member is extracted as a separate functional component from the bus bar and terminal assembly. It provides the attachment function independently, allowing the bus bar to maintain its simple electrical connection function while the holding member provides secure mechanical support and positioning through the protrusion-receptacle interface.
Solution Approach 2:
The protrusion on the bus bar and the corresponding receptacle on the holding member create a self-aligning, self-positioning attachment mechanism. When assembled, the protrusion automatically fits into the receptacle, providing secure holding and precise positioning without requiring additional fastening operations or complex adjustment mechanisms.
Data Source
AI summary
A battery pack include: batteries; a bus bar (a negative-electrode-side connection terminal) that electrically connects the batteries and a terminal of an external device (the terminal attached to a power cable); and a holding member (a case) which holds the negative-electrode-side connection terminal and to which the terminal of the power cable is attached with the negative-electrode-side connection terminal interposed therebetween. The negative-electrode-side connection terminal extends in an elongated shape toward a side of the case (holding member) having an insulating property. The negative-electrode-side connection terminal includes a protrusion projecting toward the side of the case. The protrusion extends in the lateral direction of the negative-electrode-side connection terminal on a distal end side in the longitudinal direction of the negative-electrode-side connection terminal. The case includes an attachment portion (an insertion portion) to which the protrusion is attached with a gap at least partially provided.