Busbar Connector Housing Structure for Stable Bolt Attachment
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Solution Overview
Problem
The existing inter-terminal connection structures require multiple bolts for attaching and detaching energizing members, leading to inefficient work processes.
Innovation Solution
A busbar unit with a bolt fastening portion and a connector terminal portion separated by a molded resin portion, including a projection that contacts the battery pack, and a fixing mechanism to improve work efficiency by supporting the busbar unit during attachment and detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If both ends of the energizing member are bolted in the inter-terminal connection structure, then the connection strength is improved, but the work efficiency relating to attachment and detachment deteriorates due to requiring multiple bolts to be operated
Solution Approach 1:
The connection structure is segmented into two distinct types: a bolt fastening portion for strong electrical connection and a connector terminal portion for easy attachment/detachment. This segmentation allows each end of the busbar to serve different functions, resolving the contradiction between connection strength and work efficiency.
Solution Approach 2:
Different connection methods are applied to different locations of the busbar. One end uses bolt fastening for strong connection where electrical connection is critical, while the other end uses connector terminals for easy operation where frequent attachment/detachment is needed. This local differentiation optimizes both strength and productivity.
2Reliability
If both ends of the energizing member are bolted, then the electrical connection reliability is improved, but the ease of operation deteriorates due to complex bolt operations
Solution Approach 1:
The busbar connection structure is divided into two segments with different connection mechanisms: bolt fastening for reliable electrical connection and connector terminals for easy operation. This segmentation allows each endpoint to optimize for its primary function.
Solution Approach 2:
The busbar is designed with multi-functional endpoints: one end provides bolt fastening for both mechanical strength and electrical connection, while the other end provides connector terminals for both electrical connection and easy attachment/detachment. This multi-functionality resolves the contradiction between reliability and ease of operation.
3Device complexity
If the busbar unit is not properly supported during attachment and detachment, then the device complexity is reduced, but the ease of operation deteriorates due to busbar rotation
Solution Approach 1:
The busbar unit provides self-support through its own structure during attachment and detachment operations. The molded resin portion acts as a built-in support mechanism that prevents rotation without requiring external fixtures or complex support systems, maintaining simplicity while improving ease of operation.
Solution Approach 2:
The molded resin portion serves as a single-use, non-reusable support feature that is integrated into the busbar unit. It provides temporary support during the attachment/detachment process and then serves its primary function as part of the connector housing, eliminating the need for separate reusable support mechanisms.
Data Source
AI summary
A busbar unit includes a busbar including a bolt fastening portion and a connector terminal portion, and a molded resin portion for covering the busbar. The molded resin portion includes a connector housing portion for covering the connector terminal portion by being provided apart from a side surface of a battery pack in a first direction to face the side surface, an intermediate covering portion for covering an intermediate portion of the busbar extending out from the connector housing portion and a projection projecting from the connector housing portion toward the side surface of the battery pack, the projection contacting the side surface of the battery pack.