Energy Storage Terminal Structure for Low-Stress Bus Bar Connection
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Solution Overview
Problem
Conventional energy storage apparatuses face issues with connection strength, electrical resistance, and reliability due to stress concentration at connection points between the circuit board, electrical devices, and bus bars, leading to decreased performance.
Innovation Solution
An energy storage apparatus design where the circuit board, electrical device, and bus bar are electrically and mechanically connected at a single point, reducing stress concentration and minimizing resistance in the current path by fixing the device terminal and bus bar to the board terminal, thereby enhancing reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the bus bar is connected to the current sensor unit by a bolt and nut at a portion different from the BMS circuit board connection, then the connection strength between bus bar and current sensor unit is improved, but stress concentrates on the soldering connection between current sensor unit and BMS circuit board
Solution Approach 1:
The patent merges the electrical connection and mechanical fastening functions into a single integrated terminal structure. The terminal includes a body portion electrically connected to the BMS circuit board and a protruding portion for bus bar attachment, combining multiple connection functions into one component to eliminate stress concentration at separate connection points
Solution Approach 2:
The terminal acts as an intermediary component between the BMS circuit board and the bus bar. It provides a mechanical fastening structure (protruding portion with hole) that mediates the connection, distributing mechanical stress away from the soldering joint while maintaining electrical continuity
2Ease of manufacture
If multiple conductive elements are connected in series, then the connection work becomes simpler, but the accumulated resistance values decrease the performance of the energy storage apparatus
Solution Approach 1:
The patent merges multiple connection functions into a single terminal component that simultaneously provides electrical connection to the BMS circuit board and mechanical fastening for the bus bar, eliminating the need for series connections and reducing accumulated resistance
Solution Approach 2:
The terminal is segmented into a body portion for circuit board connection and a protruding portion for bus bar attachment, allowing direct electrical connection without intermediate series connections, thereby reducing resistance accumulation while maintaining manufacturing simplicity
Data Source
AI summary
An energy storage apparatus includes an energy storage device, a circuit board, an electrical device, and a bus bar. The circuit board includes a board and a board terminal electrically connected to the energy storage device and fixed to the board. A device terminal fixed to the electrical device and the bus bar are fixed together at once to the board terminal to be electrically connected to the board terminal.