Battery Pack Busbar Module Rib Damping for Vibration Noise
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Solution Overview
Problem
Existing battery pack busbar modules do not effectively prevent abnormal noise at the joint portion between the busbar accommodating portion and the resin cover portion when subjected to external vibrations.
Innovation Solution
A battery pack busbar module design featuring a rib projecting from the cover portion that abuts the busbar accommodating portion, allowing for elastic deformation and strong, rigid locking, which maintains a gap between components even under vibration, preventing noise from repeated contact and separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the cover portion is directly locked to the busbar accommodating portion without additional damping structures, then the locking mechanism is simple, but abnormal noise occurs due to vibration-induced contact and separation
Solution Approach 1:
A rubber damping member is introduced as an intermediary element between the cover portion and the busbar accommodating portion. This damping member absorbs vibrations and prevents direct contact and separation between the resin components, thereby eliminating abnormal noise while maintaining a relatively simple locking mechanism structure.
Solution Approach 2:
The rubber damping member functions as a flexible element that deforms under vibration, providing continuous contact between the cover portion and the busbar accommodating portion. This flexible intermediary prevents the repeated contact and separation of rigid resin parts that causes noise, while allowing the locking mechanism to remain simple.
2Object-affected harmful factors
If a rigid locking structure is used to prevent noise, then noise prevention is effective, but the closure operation becomes difficult requiring large pressing force
Solution Approach 1:
The rubber damping member provides flexibility to the locking structure, allowing it to deform during the closure operation. This flexibility enables the cover to be closed with relatively small pressing force, as the damping member can compress and accommodate the movement without requiring excessive force, while still maintaining continuous contact to prevent noise.
Solution Approach 2:
The rubber damping member changes its physical state from a compressed condition during closure to a relaxed condition during normal operation. During closure, it compresses to allow easy operation, then maintains continuous contact in its relaxed state to prevent vibration-induced noise, thus adapting its parameters to satisfy both requirements.
3Object-affected harmful factors
If the cover portion is continuously pressed against the busbar accommodating portion, then noise is prevented, but the structure becomes complex and difficult to manufacture
Solution Approach 1:
The rubber damping member serves as a simple intermediary component that can be easily manufactured and integrated into the existing locking structure. It provides continuous contact and vibration damping through its inherent material properties, eliminating the need for complex active control mechanisms or additional actuating components.
Solution Approach 2:
The rubber damping member automatically performs its noise-prevention function through its elastic properties and continuous contact with the busbar accommodating portion. It self-adjusts to vibrations and maintains continuous contact without requiring external control systems, complex mechanisms, or additional manufacturing steps beyond basic integration.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design effectively prevents abnormal noise caused by vibrations by ensuring a strong and rigid abutment between the cover and busbar accommodating portions, while also facilitating easy closure of the cover portion with a relatively small pressing force.
Implementation Method 1
when external vibrations are imparted to the busbar module which is installed in the battery pack mounded in a vehicle such as a motor vehicle
Implementation Method 2
a rubber damping member is interposed between the cover portion and the busbar accommodating portion
Data Source
AI summary
Abnormal noise at a battery pack busbar module is prevented. A battery pack busbar module includes busbar accommodating portions each accommodate busbars which connect in series batteries, cover portions coupled by hinges to one of side edges of openings in the busbar accommodating portions to cover the openings, and lock portions to lock the cover portions by bringing first engagement portions provided on the other side edges of the busbar accommodating portions and second engagement portions provided on the cover portions into engagement with each other, and ribs projecting from the cover portions to come into abutment with the busbar accommodating portions are formed in positions spaced away from the lock portions, a height of the ribs being set such that the second engagement portions are not brought into engagement with the first engagement portions when the ribs abut the busbar accommodating portions.