Pivoting Bus Bar Terminal Assembly for Battery Pack Maintenance
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Solution Overview
Problem
Existing vehicle battery packs require the removal of all nuts along the bus bar module to access individual battery cells, making it cumbersome to gain quick access while maintaining voltage and current supply to vehicle components.
Innovation Solution
A battery pack assembly with a housing and hingedly attached lids that pivot between open and closed positions, allowing terminal connectors to communicate with battery cell terminals, enabling easy access and removal of cells while maintaining electrical connectivity through a circuit board and elongated member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bus bar module is used to carry voltage and current to vehicle components, then electrical connectivity is maintained, but access to individual battery cells becomes difficult requiring removal of all nuts along the module
Solution Approach 1:
The battery pack is divided into modular sections with individual battery cells that can be accessed independently. The bus bar module is segmented into multiple detachable terminal connectors, each associated with specific battery cells, allowing selective access without disrupting the entire electrical system.
Solution Approach 2:
The terminal connectors are designed with movable components that enable dynamic reconfiguration. The connectors can be quickly detached and reattached, transforming the rigid electrical connection system into a flexible one that allows rapid access to battery cells while maintaining electrical connectivity when closed.
2Reliability
If all nuts along the bus bar module must be removed to access battery cells, then electrical connectivity is maintained through the complete module, but time and complexity of cell removal increases
Solution Approach 1:
The electrical connection system is segmented into independent terminal connector units, each capable of being detached separately. This allows technicians to access specific battery cells by removing only the relevant terminal connector and associated nuts, rather than the entire bus bar module, significantly reducing access time.
Solution Approach 2:
The terminal connectors are pre-configured with alignment features and quick-release mechanisms that enable rapid detachment. The modular design with pre-positioned fasteners and electrical connections allows for swift access to battery cells without requiring complex disassembly procedures.
3Reliability
If a bus bar module extends the entire length of the battery pack to provide electrical connectivity, then voltage and current are supplied to vehicle components, but the complexity of the device increases
Solution Approach 1:
The continuous bus bar module is divided into multiple independent terminal connector segments distributed along the battery pack. Each segment handles electrical connections for specific battery cells, reducing the complexity of the overall structure by breaking down the monolithic bus bar into manageable, modular units that are easier to manufacture, install, and maintain.
Solution Approach 2:
The terminal connectors are designed as universal modules that can be standardized across different battery cell positions. Each connector performs multiple functions: electrical connection, mechanical support, and quick-release capability. This multi-functionality reduces the need for specialized components, thereby simplifying the overall device complexity.
Data Source
AI summary
Embodiments described herein generally relate to a battery pack assembly. The battery pack assembly includes a housing and a plurality of battery cells. The housing includes a pair of sidewalls and a pair of end walls that define a cavity, and a pair of lids. Each lid of the pair of lids has an interior surface and each lid of the pair of lids moves between an open position and a closed position. A plurality of terminal connectors are positioned on each inner surface of each of the pair of lids. The plurality of battery cells are positioned within the cavity. Each battery cell of the plurality of battery cells has a pair of terminals. When each lid is in the closed position, each of the plurality of terminal connectors are communicatively coupled to a corresponding terminal of the pair of terminals of each battery cell.