Busbar Frame Layout for Low-Profile Energy Storage Packs
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Solution Overview
Problem
The existing energy storage apparatus has a large protrusion dimension due to the cover being on top of the terminal surface and the connector being on the top, making it impossible to meet the manufacturer's request for reducing the size, particularly in applications like automobiles.
Innovation Solution
The energy storage apparatus features a busbar frame with a body on the terminal surface and a connector holder on the side surface, allowing for a reduction in protrusion dimension by repositioning the connector and using a coupling portion that can be bent for improved workability and reduced part count, along with a locking mechanism to prevent unintended detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the cover is disposed on the upper side of the terminal surface and the connector is formed on the top of the cover, then the connector is easily accessible, but the dimension in the height direction becomes large
Solution Approach 1:
The connector holder is disposed on the side surface of the energy storage device group rather than on the top surface, changing the spatial dimension from vertical (height direction) to horizontal (side direction). This dimensional transition reduces the height dimension while maintaining connector accessibility from the side.
2Device complexity
If the cover structure is used to hold busbars and connectors, then the structure is simple, but the height dimension increases
Solution Approach 1:
The busbar frame is disposed on the side surface instead of using a top cover structure, transitioning from vertical stacking to horizontal arrangement. This reduces the height dimension while maintaining structural simplicity through the integrated busbar frame design.
Solution Approach 2:
The connector holder is extracted from the top cover structure and positioned separately on the side surface, allowing the busbar holding function and connector holding function to be spatially separated, thus reducing the height dimension.
3Ease of manufacture
If the coupling portion is made bendable, then the workability improves and part count reduces, but the structural strength may be compromised
Solution Approach 1:
The coupling portion is designed with bendability to enable dynamic adjustment during installation, improving workability. The coupling can be bent to connect the busbar frame to the side surface, facilitating easier assembly while maintaining sufficient structural strength through the bending connection.
Data Source
AI summary
An energy storage apparatus includes: an energy storage device group in which a terminal surface and a side surface intersecting the terminal surface are formed by a plurality of arrayed energy storage devices; and a busbar frame holding a plurality of busbars. The busbar frame is provided with a body holding the busbar and disposed on the terminal surface, a connector holder having a connector, to which an external connector is connected, and disposed on the side surface, and a coupling portion coupling the body and the connector holder.