Copper Bar Isolation Bracket for Wear and Short-Circuit Prevention
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Solution Overview
Problem
In electric vehicle battery packs, the fixing of copper bars often leads to abrasion and short circuits due to the bolt head interacting with adjacent copper bars, with existing protective caps being inadequate in preventing wear and loosening, especially during dynamic conditions.
Innovation Solution
A copper bar isolation bracket with a supporting portion, connecting portion, and fixing portion, featuring a fixing device that separates adjacent copper bars, preventing direct contact and wear by creating a gap between the fixing device and the supporting portion, and using a non-metallic material to prevent short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a bolt head protecting cap is used to protect the bolt head, then the bolt head is protected, but the protecting cap is easy to loosen and fall off in a non-static state and may still cause abrasion to the adjacent copper bar
Solution Approach 1:
The patent introduces an isolation bracket as an intermediary component between the bolt head and the adjacent copper bar. This bracket includes a first isolation portion that contacts the bolt head and a second isolation portion that contacts the adjacent copper bar, effectively mediating the interaction and preventing direct contact while maintaining stable positioning during vehicle movement
Solution Approach 2:
The isolation bracket is designed to be self-fixed to the copper bar through the fixing device, eliminating the need for additional fastening mechanisms. The bracket automatically maintains its position and continues to provide isolation protection even during dynamic conditions, serving itself without external intervention
2Object-affected harmful factors
If a copper bar protecting cap is used to cover the copper bar, then the copper bar is protected from direct contact, but the bolt head, protecting cap and adjacent copper bar are not separated, leaving risk of wear after wearing through the protecting cap
Solution Approach 1:
The isolation bracket is segmented into multiple functional portions: a first isolation portion for contacting the bolt head, a second isolation portion for contacting the adjacent copper bar, and a fixing device for securing the bracket. This segmentation allows each portion to perform its specific isolation function independently, providing comprehensive protection
Solution Approach 2:
The isolation bracket serves as an intermediary structure that physically separates the bolt head from the adjacent copper bar. By introducing this intermediate component, the patent ensures that even if the protecting cap wears through, the bolt head remains isolated from the copper bar by the bracket structure
3Productivity
If copper bars are fixed closely together to improve packing efficiency, then space utilization is improved, but the bolt head easily causes abrasion of the insulation layer of an adjacent copper bar
Solution Approach 1:
The isolation bracket is positioned between closely spaced copper bars, serving as an intermediary that enables tight packing while preventing harmful contact. The bracket's compact design allows it to fit in the limited space between adjacent copper bars without compromising packing efficiency
Solution Approach 2:
The isolation bracket uses a thin-walled structure that provides effective isolation while occupying minimal space. This thin-film approach allows the copper bars to be positioned closely together for high packing efficiency while the bracket maintains sufficient isolation to prevent abrasion
Data Source
AI summary
A copper bar isolation bracket includes a supporting portion, a connecting portion and a fixing portion. The connecting portion is provided between the supporting portion and the fixing portion, and is separately connected to the supporting portion and the fixing portion; the fixing portion is provided with a fixing device, and the fixing device is configured to fix a first copper bar on the fixing portion; a spacing for accommodating the first copper bar and the fixing device is formed between the supporting portion and the fixing portion; and a gap is formed between the fixing device and the supporting portion; the supporting portion is configured to support a second copper bar.