Flexible Bus Bars for Battery Pack Assembly and Vibration
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Solution Overview
Problem
Existing battery packs face challenges in assembling electrode terminals due to dimension and assembling tolerances, and are prone to damage and electrical contact defects from vibrations when using rigid bus bars.
Innovation Solution
The use of flexible bus bars formed by stacking thin plates with bent parts, coupled to electrode terminals via socket terminals and sockets with elastic contactors, which absorb vibrations and provide a secure electrical connection without the need for additional tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid bus bars with through-holes are used to connect electrode terminals, then the electrical connection is established, but the assembly difficulty increases due to dimension and assembling tolerances
Solution Approach 1:
The bus bar material property is changed from rigid to flexible, allowing it to adapt to dimensional variations and tolerance accumulations during assembly, thereby facilitating easier connection while maintaining reliable electrical contact
Solution Approach 2:
The bus bar is designed with flexible characteristics enabling dynamic adaptation to assembly variations, allowing the rigid through-holes to accommodate dimensional tolerances through the flexible material's ability to deform and conform during the insertion process
2Reliability
If rigid bus bars are fixed to electrode terminals, then the electrical connection is established, but the vulnerability to vibration damage increases
Solution Approach 1:
The bus bar's mechanical property is changed from rigid to flexible, enabling it to absorb vibration energy through elastic deformation rather than transmitting stress to the electrode terminals, thus preventing damage while maintaining electrical connection
Solution Approach 2:
The flexible bus bar acts as a pre-designed cushioning element that absorbs vibration shocks before they can reach and damage the electrode terminals, protecting the connection system from harmful vibrational forces
3Reliability
If through-holes are formed in bus bars for electrode terminal insertion, then the electrical connection is established, but the assembly precision requirements increase
Solution Approach 1:
The bus bar is transformed from a rigid component with fixed through-holes to a flexible component that can deform during assembly, allowing it to accommodate dimensional and positional variations without requiring high assembly precision
Solution Approach 2:
The flexible bus bar dynamically adapts its shape during the assembly process to match the actual positions of electrode terminals, compensating for manufacturing tolerances and reducing the need for high assembly precision
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
Facilitates easy connection of electrode terminals, absorbs vibrations, prevents damage, and maintains stable electrical contact, reducing the risk of defects and simplifying maintenance.
Implementation Method 1
flexible bus bars formed by stacking a plurality of thin plates, having bent parts formed at the center thereof
Implementation Method 2
socket terminals having a plurality of elastic contactors extendedly formed at one sides of cylindrical bodies thereof
Data Source
Figure 1
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AI summary
Provided is a battery pack including flexible bus bars formed in a form in which a plurality of thin plates are stacked, having bent parts formed at the center thereof, and having both sides coupled to a positive electrode terminal and a negative electrode terminal protruding outwardly of battery modules to electrically connect electrode terminals of the battery modules to each other.