Centralized Busbar Wire Holding for EV Battery Protection
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Solution Overview
Problem
The existing busbar module for electric vehicles and hybrid electric vehicles is prone to damage from vibrations and collisions due to the positioning of the electrical wire connected to the series-connected battery cells, which can lead to external components coming into contact with the wire and causing damage or disconnection.
Innovation Solution
The electric wire holding portion is rearranged to be central and enclosed within a box-shaped structure, with a cover protecting the connection between the wire and the electrode, reducing the risk of external contact and damage during vehicle operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the electrical wire is positioned in the accommodating groove extending from the edge of the plate body, then the wire can be easily accessed and connected, but the wire is exposed to external components and prone to damage from vibrations and collisions
Solution Approach 1:
The electrical wire is repositioned from an edge-based accommodating groove to a central position on the plate body, utilizing the central area as a new spatial zone for wire placement. This dimensional relocation moves the wire away from vulnerable edge regions prone to vibration and collision damage, while the central positioning maintains operational accessibility.
Solution Approach 2:
A dedicated wire holding portion is introduced as an intermediary structure between the electrical wire and the plate body. This holding portion secures the wire in the central region, providing mechanical support and protection while maintaining electrical connection functionality, thus mediating between protection requirements and operational needs.
2Reliability
If the electrical wire is positioned centrally on the plate body, then the wire is protected from external contact and vibration damage, but the plate structure becomes more complex
Solution Approach 1:
The wire holding portion is designed to perform multiple functions: it secures the electrical wire in the central protected region, provides mechanical support against vibrations, and maintains the wire's electrical connection capability. By consolidating these functions into a single structural element, the overall plate structure complexity is minimized while achieving reliable wire protection.
3Reliability
If a dedicated overlapping area on the plate is provided for the electrical wire, then the wire is securely positioned and protected, but the plate design becomes more complicated and space-consuming
Solution Approach 1:
The wire holding portion is merged with the central region of the plate body, combining the wire positioning function with the existing central structural area. This integration eliminates the need for a separate dedicated overlapping area, reducing the overall plate area requirement while maintaining secure wire positioning and protection through the centralized holding structure.
Data Source
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AI summary
A power supply apparatus 1 includes: a battery cell assembly 2 including battery cells 3 having a positive terminal 11 at one end and a negative terminal 12 at the other end; a busbar module 5 attached to the assembly 2 and configured to connect the cells 3 in series with each other; and a pair of electric wires 9 connected to electrodes 11, 12 taking out a voltage of the series-connected cells 3. The busbar module 5 includes: bus bars 6 configured to connect the positive terminal 11 and the negative terminal 12 of the mutually adjacent battery cells 3 of the assembly 2; a plate 8 disposed on the assembly 2 with the bus bars 6 attached thereto; and an electric wire holding portion 18 provided on the plate 8 configured to hold one electric wire 9a of the pair of the electric wires 9. The electric wire holding portion 18 extends in the arrangement direction X in which the cells 3 are arranged at a central portion of the plate 8 in the width direction Z orthogonal to the direction X of the battery cells 3.