Busbar Holding Structure with Projection Locking
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Solution Overview
Problem
Conventional busbar modules for vehicular battery packs are large, heavy, and costly due to unnecessary components, and require high force for assembly, leading to inefficiencies in manufacturing and potential issues with busbar rotation during welding and current carrying.
Innovation Solution
A busbar holding structure featuring a bottom wall with a partition wall and lock portion, along with perpendicular projections that fit into the busbar, allowing for secure positioning without a circumferential wall, reducing size, weight, and manufacturing costs, while preventing busbar rotation during welding and current carrying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional busbar fixing unit with frame-shaped side wall and multiple lock projections is used, then the busbar can be fixedly housed without play, but the size, weight, and manufacturing cost increase
Solution Approach 1:
The invention extracts and removes the unnecessary frame-shaped side wall from the busbar fixing unit, retaining only the essential bottom wall with simplified positioning structures. This extraction eliminates the heavy circumferential enclosure while preserving the core function of securing the busbar through the bottom wall's projections and recesses.
Solution Approach 2:
The invention applies local quality by providing positioning projections and recesses only at specific locations on the bottom wall where needed for busbar securing, rather than using a comprehensive frame structure. The bottom wall has localized features (projections at corners, recesses at center) that provide sufficient positioning stability without the need for a complete circumferential enclosure.
2Reliability
If a conventional busbar fixing unit with frame-shaped side wall is used, then the busbar is surrounded and held fixedly, but the manufacturing cost increases
Solution Approach 1:
The invention extracts and removes the frame-shaped side wall structure, reducing the amount of material and manufacturing steps required. The bottom wall alone suffices to provide the necessary fixation function when equipped with appropriate projections and recesses, eliminating the complex four-wall enclosure.
Solution Approach 2:
The invention merges the functions of the bottom wall and side walls into a single integrated bottom wall structure. The bottom wall simultaneously provides support, positioning, and fixation functions that were previously distributed across multiple components (bottom wall + four side walls), simplifying manufacturing.
3Reliability
If busbar lock projections are deformed outward elastically to insert the busbar, then the busbar can be fixedly housed, but strong insertion force is required reducing work efficiency
Solution Approach 1:
The invention inverts the conventional approach by having the busbar actively engage with the fixing unit rather than the fixing unit actively deforming to grip the busbar. The busbar's own deformation causes it to snap into the positioning recesses on the bottom wall, eliminating the need for strong external insertion force to deform lock projections.
Solution Approach 2:
The busbar performs self-service by using its own elastic deformation to achieve secure positioning in the fixing unit. When inserted, the busbar naturally deforms and snaps into the recesses on the bottom wall, securing itself without requiring the fixing unit to actively deform or apply strong gripping forces.
4Reliability
If a conventional busbar fixing unit with central receiving portion and lock projections is used, then the busbar can be sandwiched and held fixedly, but the structure becomes complex
Solution Approach 1:
The invention extracts and removes the frame-shaped side wall and complex lock projection system, retaining only the essential bottom wall with simplified positioning features. The bottom wall's corners and center provide sufficient positioning capability without the need for a comprehensive frame structure with multiple active locking components.
Solution Approach 2:
The invention applies local quality by providing positioning projections at specific locations (corners) and recesses at specific locations (center) on the bottom wall, creating a simplified structure that provides localized positioning and fixation functions without the complexity of a complete frame structure with distributed lock projections.
Data Source
AI summary
A busbar holding structure holds at least one of plural busbars to a wires routing body. The plural busbars electrically connect plural cell batteries constituting a battery assembly. The busbar holding structure includes a bottom wall, a partition wall erected from a portion of a peripheral edge of the bottom wall, a lock portion provided on the partition wall and configured to lock a side end portion of the busbar on the wires routing body, and a first projection that projects perpendicularly from the bottom wall and is to be fitted in a through-hole provided in the busbar. A fitting gap between the first projection and the through-hole is set so as to restrict an inclination angle of the busbar with respect to the first projection and to thereby prevent the busbar from being unlocked from the lock portion.