Segmented Busbar Insulation Sleeves for Complex Battery Pack Bends
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Solution Overview
Problem
The existing insulation methods for busbars in battery packs, such as integral heat shrinkable tubes and powder spraying, fail to ensure high insulation withstand-voltage reliability due to defects like whiteness, wrinkles, air bubbles, and high material and process costs, especially with complex busbar structures.
Innovation Solution
A connecting assembly comprising multiple independent heat shrinkable sleeves that segmentally cover different parts of the busbar, reducing bending lengths and costs, and improving insulation reliability by minimizing material wear during the heating process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an integral heat shrinkable tube is used to insulate the busbar, then the insulation coverage is continuous, but the tube generates defects such as whiteness, wrinkles, air bubbles, and tearing at bending positions, failing to meet insulation reliability requirements
Solution Approach 1:
The patent divides the single integral heat shrinkable tube into multiple segmented heat shrinkable tubes (first, second, and third heat shrinkable tubes) that cover different portions of the busbar. The third heat shrinkable tube specifically covers the bent connection portion, while the first and second tubes cover the main body and extending portions. This segmentation eliminates the defects caused by bending a single long tube while maintaining continuous insulation coverage.
2Reliability
If powder spraying, dip molding, or extrusion processes are used to insulate the busbar, then insulation coverage is achieved, but the material cost and process cost are high
Solution Approach 1:
The patent uses multiple short sections of heat shrinkable tubes instead of expensive powder spraying, dip molding, or extrusion processes. These heat shrinkable tubes are simpler, more cost-effective materials that can be easily applied and removed if needed, providing the same insulation function at lower material and process costs.
3Adaptability or versatility
If the busbar has complex extensions and bending structures, then the busbar can meet electrical connection requirements, but the insulation becomes more difficult and costly
Solution Approach 1:
The patent applies different insulation solutions to different portions of the busbar based on their specific requirements. The third heat shrinkable tube with larger diameter specifically covers the bent connection portion, while the first and second tubes cover the main body and extending portions. This localized approach allows the insulation system to adapt to the complex geometry without increasing overall complexity or cost.
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 solution simplifies the structure and reduces manufacturing costs while enhancing insulation withstand-voltage reliability by using shorter, less-bent insulating sleeves that effectively cover complex busbar geometries without defects, ensuring the battery pack meets insulation requirements.
Implementation Method 1
The first insulating sleeve, the second insulating sleeve and the third insulating sleeve each are a heat shrinkable tube
Data Source
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AI summary
The present invention provides a connecting assembly and a battery pack, the connecting assembly comprises a busbar, a first insulating sleeve, a second insulating sleeve and a third insulating sleeve. The busbar comprises a main body portion, an extending portion, and a bent connection portion. The first insulating sleeve covers the main body portion. The second insulating sleeve covers the extending portion. The third insulating sleeve comprises a first covering portion, the first covering portion covers the bent connection portion. Because the first insulating sleeve, the second insulating sleeve and the third insulating sleeve are independent components, and they segmentally cover different parts of the busbar, so that each of them has a shorter length and less portion required to be bent, thereby facilitating the first insulating sleeve, the second insulating sleeve and the third insulating sleeve to be respectively sheathed on the different parts of the busbar.