Connection Module Insulating Protector Load Distribution
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Solution Overview
Problem
Conventional connection modules between external connection busbars and electricity storage elements face reliability issues due to deformation caused by high loads applied to insulating protectors during bolt-fastening, which can lead to reduced connection reliability.
Innovation Solution
A connection module design that includes a support plate portion and inner surface abutting portions within the insulating protector to distribute and release the load to the frame outer wall, reducing the stress on the insulating protector during bolt-fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an external connection component is bolt-fastened to the external connection busbar, then the connection between the external device and the electricity storage element group is established, but a pressing load, pulling load, or torsional load is applied to the insulating protector, causing deformation and reduced reliability
Solution Approach 1:
The frame acts as an intermediary structure that receives and distributes the loads from the insulating protector during bolt-fastening operations. Instead of the insulating protector bearing the full load, the frame serves as a mediator to transfer these forces to the busbar and supporting structures, thereby protecting the insulating protector from deformation while maintaining connection reliability
Solution Approach 2:
The insulating protector is pre-installed onto the busbar before the external connection component is bolt-fastened. This preliminary positioning ensures that the insulating protector is already in place to provide electrical insulation and structural support during the subsequent bolt-fastening process, preventing load-induced deformation
2Reliability
If the insulating protector is made of synthetic resin for insulation, then electrical insulation is provided, but the material deforms under high bolt-fastening loads
Solution Approach 1:
The connection system uses a composite structure combining the synthetic resin insulating protector with metal components (busbar, frame, and external connection component). The metal frame and busbar provide mechanical strength to bear the bolt-fastening loads, while the synthetic resin insulating protector provides electrical insulation, allowing each material to perform its optimal function without compromising the other
Solution Approach 2:
The frame serves as a mediator between the synthetic resin insulating protector and the metal busbar, distributing the mechanical loads away from the insulating protector while maintaining the electrical insulation function. This intermediary structure prevents the insulating protector from directly bearing high mechanical stresses that would cause deformation
Data Source
AI summary
A connection module includes a negative electrode external connection busbar to which an external connection component is to be bolt-fastened; a positive electrode external connection busbar to which an external connection component is to be bolt-fastened; and an insulating protector configured to hold the external connection busbars in an insulated manner. The insulating protector includes a support plate portion including a support plate surface that faces and extends along an outer surface of a frame outer wall for accommodating an electricity storage element group in a state in which the connection module is attached to the electricity storage element group, at least the support plate surface being configured to abut against an outer surface of the frame outer wall so as to support the insulating protector when the external connection components are bolt-fastened to the first external connection busbar and the second external connection busbar.