Busbar Module Lock Member Integration for EV Power Supply
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing power supply systems for hybrid and electric vehicles require a complex configuration and increased resin material for busbar fitting portions, leading to higher material costs and environmental impact.
Innovation Solution
A power supply system with a busbar module that integrates a lock member from the bulkhead to restrict the busbar and an abutment portion on the terminal to prevent rotation, allowing for a simpler and smaller busbar fitting portion, reducing resin material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the busbar locking portion and terminal locking portion are provided independently in the busbar fitting portion, then the busbar and terminal can be securely locked, but the busbar fitting portion becomes large and complex requiring increased resin material
Solution Approach 1:
The patent combines the busbar locking portion and terminal locking portion into a single integrated lock member structure. The lock member includes a busbar locking portion that projects toward the busbar and a terminal locking portion with a slit for the terminal, merging two previously separate locking mechanisms into one unified component that provides both locking functions while reducing overall complexity and material usage
Solution Approach 2:
The lock member is designed as a multi-functional component that simultaneously performs busbar locking and terminal locking functions. By making the lock member universal in its capability to secure both the busbar and terminal, the design eliminates the need for separate dedicated locking components for each element, thereby simplifying the overall busbar fitting portion structure
2Reliability
If the busbar locking portion and terminal locking portion are provided independently, then reliable locking is achieved, but the amount of resin material increases leading to higher costs and CO2 emissions
Solution Approach 1:
The patent combines the busbar locking portion and terminal locking portion into a single integrated lock member structure. The lock member includes a busbar locking portion that projects towards the busbar and a terminal locking portion with a slit for the terminal, merging two previously separate locking mechanisms into one unified component that provides both locking functions while reducing overall complexity and material usage
Solution Approach 2:
The patent eliminates the unnecessary separation between busbar locking and terminal locking components, discarding the redundant material that would be required for multiple independent locking portions. By recovering the material efficiency through integration, the design reduces resin material consumption while maintaining adequate locking security
Data Source
AI summary
A power supply system including a plurality of batteries includes a busbar, a terminal and a busbar module. The busbar connects a first electrode of one of the batteries with a second electrode of another one of the batteries. The terminal is mounted on the busbar and is contacted with the first electrode. The busbar module has a bulkhead defining a space accommodating the busbar. A locking member is extended from the bulkhead into the space and restricts the busbar. An abutment portion is provided at an edge part of the terminal. The abutment portion abuts the locking member when the terminal is rotated about the first electrode.