Connection Module Busbar Holder Fixing-Reinforcement Design
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Solution Overview
Problem
Conventional power storage module arrangements with external connection busbars face reliability issues due to torque loads generated during bolt tightening, which can cause displacement and affect the connection between external connection busbars and output electrode terminals.
Innovation Solution
A connection module with a busbar holding module and an external connection busbar holder that includes insulating protectors with fixing portions and engaging portions, where the fixing-reinforcement portions deform to fill clearances between the fixing and fixed portions, preventing movement and torque load transmission to the busbars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If predetermined clearances are provided between the external connection busbar holder member and locking members to absorb product variations, then ease of assembly is improved, but reliability of connection deteriorates due to rattling and torque load transmission
Solution Approach 1:
A resin layer is introduced as an intermediary substance between the external connection busbar holder member and the locking members. This resin layer fills the predetermined clearances and gaps, preventing rattling while accommodating product variations. The resin acts as a mediator that transmits assembly tolerance benefits without transmitting harmful torque loads to the busbar connections, thus resolving the contradiction between ease of assembly and connection reliability.
2Adaptability or versatility
If external connection busbars are routed over long distances to supply power from one end of the power storage element group, then adaptability of power supply configuration is improved, but device complexity increases due to elongated busbars and additional holder members
Solution Approach 1:
The external connection busbar holder member is designed to serve multiple functions: it holds the external connection busbars, provides mounting positions for locking members, and incorporates recesses that receive and secure the busbars. This multi-functional design eliminates the need for separate holder members, reducing device complexity while maintaining the ability to route busbars over long distances for flexible power supply configurations.
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 solution maintains the reliability of connections between external connection busbars and output electrode terminals by suppressing torque loads, ensuring stable power transmission.
Implementation Method 1
the fixing-reinforcement portions are made of an insulating material capable of elastic deformation, and in response to engagement of the engaging portions, each of the fixing-reinforcement portions is deformed to fill a clearance between the fixing portion and the fixed portion
Data Source
AI summary
A connection module includes a busbar holding module including insulating protectors and an external connection busbar holder disposed above the busbar holding module. The insulating protectors include fixing portions joined to fixed portions provided in the power storage elements or another member to secure the external connection busbar holder. The external connection busbar holder includes a first external connection busbar and a second external connection busbar to which external connection members are bolted and engaging portions that engage with the fixing portions. Each of the fixing portions includes a fixing-reinforcement portion that is displaced to fill the clearance between the fixing portion and the fixed portion in response to engagement with the engaging portion.