Battery Pack Copper Bar Insulation Without Electrophoresis
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Solution Overview
Problem
The existing battery management systems face high manufacturing costs due to the need for an electrophoresis process to insulate the copper bar from the metal box body, which increases the risk of short circuits and electric shocks.
Innovation Solution
A battery management system with a fastening assembly that includes an insulating member and a first fastener, where the copper bar is attached to a circuit board using the fastening assembly, ensuring insulation without direct contact with the box body, thereby eliminating the need for electrophoresis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the copper bar is directly fastened to the circuit board using a metal screw post and metal box body, then the electrical connection is achieved, but the risk of short circuits and electric shocks increases due to the box body acquiring electric potential
Solution Approach 1:
An insulating member is introduced as an intermediary between the copper bar and the box body. This insulating member includes an insulating body and an insulating layer, where the insulating body supports the copper bar and the insulating layer is disposed between the insulating body and the box body, preventing direct electrical contact between the copper bar and the box body, thus eliminating the harmful electrical potential on the box body.
2Reliability
If the electrophoresis process is used to insulate the box body from the copper bar, then the insulation is achieved, but the manufacturing cost increases due to the high cost and complicated process
Solution Approach 1:
The patent replaces the expensive and complicated electrophoresis process with a simple insulating member that can be easily manufactured and assembled. The insulating member, comprising an insulating body and an insulating layer, provides effective insulation at a fraction of the cost of electrophoresis, making the manufacturing process more economical and accessible.
3Device complexity
If the copper bar is directly contacted with the metal box body through the screw post, then the assembly is simple, but the insulation between the box body and copper bar must be achieved through additional electrophoresis process
Solution Approach 1:
The insulating member merges multiple functions into a single component: it provides mechanical support for the copper bar, electrical insulation between the copper bar and box body, and structural integration with the circuit board. This consolidation eliminates the need for separate electrophoresis processing and reduces overall assembly complexity.
Data Source
AI summary
Provided are a battery management system and a battery pack. The battery pack includes a battery management system. The battery management system includes a first circuit board, a second circuit board, a copper bar and a fastening assembly. The first circuit board and the second circuit board are arranged at intervals and are fixed within a box body. The copper bar is located between the first circuit board and the second circuit board. The fastening assembly includes an insulating member and a first fastener. The copper bar is disposed to be attached to the first circuit board. A first end of the insulating member is connected to the second circuit board, and a second end of the insulating member supports the copper bar. The first fastener is fastenably connected to the insulating member and abuts against a side of the first circuit board away from the second circuit board