Embedded Bus Bar Structure for Stable Battery Pack Connections
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Solution Overview
Problem
Existing battery packs face challenges in securely positioning and connecting multiple battery cells while preventing bending deformation due to thermal contraction differences between materials, which can lead to electrical connectivity issues and reduced pack stability.
Innovation Solution
A battery pack design featuring a bus bar with a holding unit that alternately forms covered and exposed positions along its length, embedding the bus bar within a cell holder to securely connect battery cells and mitigate thermal contraction-induced bending through insert injection molding, ensuring stable electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bus bar is securely embedded in the cell holder to prevent movement, then connection stability is improved, but the structure complexity increases due to the holding unit design
Solution Approach 1:
The bus bar is embedded within the holding unit of the cell holder, creating a nested structure where one component is placed inside another. This nesting approach secures the bus bar position while integrating the holding unit with the existing cell holder structure, minimizing additional complexity.
Solution Approach 2:
The holding unit is integrated with the cell holder to form a combined structure. By merging the bus bar securing function with the existing cell holder, the design avoids adding separate independent components, thus reducing overall structural complexity while maintaining connection stability.
2Stability of the object's composition
If the bus bar is alternately covered and exposed along its length, then thermal contraction-induced bending is prevented, but the manufacturing complexity increases
Solution Approach 1:
The cell holder is divided into multiple holding units along the length of the bus bar, with each holding unit independently covering or exposing portions of the bus bar. This segmentation allows differential thermal management at different locations, preventing bending while maintaining manufacturability through modular design.
Solution Approach 2:
Different sections of the cell holder have different structures - some holding units cover the bus bar while others expose it. This local quality variation addresses thermal contraction issues at specific locations without requiring complex changes to the entire structure, simplifying manufacturing.
3Reliability
If the holding unit surrounds all four transverse edges of the bus bar, then positional stability is improved, but electrical connectivity may be compromised due to restricted access
Solution Approach 1:
The holding unit design allows dynamic adjustment between full coverage for stability and partial exposure for connectivity. By selectively covering or exposing edges at different locations along the bus bar, the structure adapts to provide both positional stability and electrical access where needed.
Solution Approach 2:
Instead of completely surrounding all transverse edges, the holding unit partially covers certain edges while leaving others exposed. This partial action provides sufficient positional stability while maintaining ease of electrical connection, avoiding the excessive constraint that would result from complete surrounding.
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 design effectively prevents bus bar movement and bending deformation, ensuring reliable electrical connections and enhanced stability of the battery pack by embedding the bus bar within a cell holder that surrounds its transverse edges, thereby addressing thermal contraction issues and maintaining pack integrity.
Implementation Method 1
preventing bending deformation due to thermal contraction differences between materials
Data Source
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AI summary
A battery pack includes battery cells, a bus bar on the battery cells and electrically connecting at least some of the battery cells to each other, the bus bar having a cross-section including transverse edges, and the transverse edges corresponding to upper and lower surfaces opposite to each other and first and second sides opposite to each other and connecting the upper and lower surfaces, and a cell holder accommodating the battery cells, the bus bar extending across the cell holder, and the cell holder including a holding unit that defines a covered position and an exposed position alternating along a length of the bus bar, the holding unit surrounding four transverse edges of the bus bar to define the covered position, and surrounding three transverse edges of the bus bar to define the exposed position.