Battery Pack Service Plug Bus Bar Layout for Space-Efficient Assembly
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Solution Overview
Problem
Conventional battery packs face inefficiencies in assembly processes, price competitiveness, and space utilization due to the need for multiple cables and components in the pack case, which increases manufacturing costs and reduces energy density.
Innovation Solution
A battery pack design featuring a service plug with a plug bus bar directly connected to the battery module assembly, utilizing a plug body and plug cover that electrically connect or disconnect the assembly without additional cables, and a plug bus bar mounted externally to the pack case, simplifying assembly and reducing internal components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple cables and fixing parts are used to connect the service plug and battery module assembly, then the service plug can be mounted to the battery pack, but the assembling process becomes complicated and manufacturing cost increases
Solution Approach 1:
The patent merges the service plug body and bus bar into a single integrated component. The bus bar is directly formed as an integral part of the plug body, eliminating the need for separate cables and fixing parts. This integration simplifies the assembling process while maintaining reliable electrical connection between the service plug and battery module assembly.
2Reliability
If multiple cables and fixing parts are used in the battery pack, then the service plug can be mounted, but the manufacturing cost increases and price competitiveness decreases
Solution Approach 1:
The service plug body and bus bar are merged into a single integrated component, reducing the total number of parts that need to be manufactured, inventoried, and assembled. This integration reduces manufacturing complexity and cost, improving price competitiveness while ensuring reliable electrical connection.
3Reliability
If separate fixing parts and cables are added to the battery pack, then the service plug can be mounted, but the space efficiency inside the pack case deteriorates
Solution Approach 1:
The integration of the bus bar into the service plug body eliminates the need for separate cables and fixing parts, thereby reducing the space occupied by these components within the pack case. This allows for better space utilization and improved energy density.
4Reliability
If additional components are added to the battery pack for service plug mounting, then the service plug can be installed, but the energy density of the battery pack is lowered
Solution Approach 1:
By merging the bus bar and service plug body into a single component, the patent eliminates the need for additional cables and fixing parts that would occupy valuable space in the battery pack. This integration maximizes the space available for active battery cells, thereby maintaining high energy density while ensuring proper service plug installation.
Data Source
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AI summary
Disclosed is a battery pack, which includes a pack case forming an appearance of the battery pack, a battery module assembly provided in the pack case and having at least one battery module, and a service plug configured to electrically connect the battery module assembly or cut off the electric connection of the battery module assembly, the service plug having a plug bus bar directly connected to the battery module assembly.