Description:FIELD
The present disclosure relates to the field of battery packs, more specifically busbar assemblies of battery packs.
DEFINITION
Tree clip fastener – The term ‘tree clip fastener’ is a fastener defined by a segmented shaft body having a plurality of pointed teeth configured thereon and a cap provided on top of the shaft body.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
A busbar assembly of a battery pack is typically covered with the help of an insulating cover to protect the high voltage busbars and their terminals from external damages and condensed water contact falling from top cooling plate. Conventionally, the insulation cover is independently attached to the busbar via snap lock fits, and the bus-bar is connected to the cell module terminals by means of separate metal hardware such as bolt, nut, and screws. Since the metallic joints are exposed during assembly, there is a possibility of a short circuit or accidental leakage of current through unintended metal contact, until no cover is provided.
In addition to the above problem, there exists an inherent concern of torque loss in busbar assemblies in the event of excessive bolt usage. More specifically, the combined effect of factors such as bolt relaxation, vibrations experienced by the busbar, thermal expansion, and elastic interaction during bolt tightening contribute to torque losses. This torque loss may later on contribute to improper contact pressure at busbar joints, and may end up with issues such as voltage drop of the battery pack, heating of the busbar, formation of gaps between the busbar joints and resultant ingress of moisture. Another issue that has been commonly observed is that more the number of hardware used, more the likelihood of them getting misplaced or being in need of repair. Moreover, hardware adds to the weight and cost of manufacturing of the battery pack.
There is therefore felt a need for a mounting arrangement for a busbar assembly of a battery pack that alleviates the aforementioned drawbacks.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
It is an object of the present disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
An object of the present disclosure is to provide a mounting arrangement for a busbar assembly of a battery pack.
Another object of the present disclosure is to provide a mounting arrangement, for a busbar assembly of a battery pack, which eliminates torque loss caused due to fastening and unfastening of bolts.
Yet another object of the present disclosure is to provide a mounting arrangement, for a busbar assembly of a battery pack, which protects the busbar connection from water ingress due to condensation in the battery pack.
Still another object of the present disclosure is to provide a mounting arrangement, for a busbar assembly of a battery pack, which reduces manufacturing and maintenance cost of the battery pack.
One object of the present disclosure is to provide a mounting arrangement, for a busbar assembly of a battery pack, which relatively reduces the overall weight by eliminating hardware like screws and bolts.
SUMMARY
The present disclosure envisages a mounting arrangement for a busbar assembly of a battery pack. The arrangement comprises a busbar having at least one first recess configured thereon, and at least one busbar terminal configured to receive the busbar thereon. The busbar terminal has at least one second recess configured thereon complementary to the first recess. A cover is disposed on the busbar. The arrangement further comprises at least one locking means configured on the cover, complementary to the first recess. The locking means is configured to be received in the first recess and the second recess to enable secure attachment of the busbar with the busbar terminal.
BRIEF DESCRIPTION OF ACCOMPANYING DRAWING
A mounting arrangement, of the present disclosure, for a busbar assembly of a battery pack will now be described with the help of the accompanying drawing in which:
Figure 1 illustrates a front view of a conventional busbar mounting arrangement;
Figure 2 illustrates a front view of the arrangement of the present disclosure, in accordance with a first embodiment of a locking means of the arrangement;
Figure 3 illustrates an isometric view of a cover of the arrangement of Figure 2;
Figure 4 illustrates a cross-sectional view of the locking means;
Figure 5 illustrates a cross-sectional view of the arrangement, of Figure 2, with a pulling tool;
Figure 6 illustrates a front view of the arrangement of the present disclosure, in accordance with a second embodiment of a locking means of the arrangement;
Figure 7 illustrates an isometric view of a cover of the arrangement of Figure 6; and
Figure 8 illustrates a cross-sectional view of the arrangement of Figure 6.
LIST OF REFERENCE NUMERALS
10 pulling tool
20 conventional mounting arrangement
25 cover of conventional mounting arrangement
30 busbar
35 busbar terminal
40 bolt
100 mounting arrangement
105 busbar
107 first recess
110 busbar terminal
112 second recess
115 cover
120 lug
122 snap-fit joint
124A, 124B projections
125 retention latch
126 hole
130 tree clip fastener
132 nut
134 spring washer
DETAILED DESCRIPTION
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, elements, components, and/or groups thereof.
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Figure 1 illustrates a conventional busbar mounting arrangement (20). The arrangement (20) includes a cover (25) configured to be disposed on a busbar (30) which in turn is configured to be mounted on a busbar terminal (35). Hardware such as bolts (40) are used to fasten the cover (25) with the busbar (30) and the busbar terminal (35).
The present disclosure envisages a mounting arrangement (100) for a busbar assembly of a battery pack with reference to Figure 2 through Figure 8 of the drawing.
The arrangement (100) comprises a busbar (105) having at least one first recess (107) configured thereon, and at least one busbar terminal (110) configured to receive the busbar (105) thereon. The busbar terminal (110) has at least one second recess (112) configured thereon complementary to the first recess (107). The arrangement (100) further comprises a cover (115) configured to be disposed on the busbar (105). At least one locking means is configured on the cover (115) complementary to the first recess (107). The locking means is configured to be received in the first recess (107) and the second recess (112) to enable secure attachment of the busbar (105) with the busbar terminal (110).
In accordance with a first embodiment, the locking means includes a lug (120) configured to extend from the cover (115), more specifically from an operative bottom surface of the cover (115). In an embodiment, the lug (120) is of a polymeric material. The lug (120) has an annular snap-fit joint (122) configured at an operative free end thereof. The lug (120) is configured to be received in the first recess (107) and the second recess (112), when the cover (115) is pressed against the busbar (105), to enable interlocking of the snap-fit joint (122) in the second recess (112). The snap-fit joint (122) ensures a positive lock between the busbar terminal (110) and the busbar (105) when the cover (115) is pressed upon the busbar (105).
In another embodiment, the locking means includes a pair of projections (124A, 124B) configured on the cover (115), on opposite sides of the lug (120). The projections (124A, 124B) are configured to maintain a contact force of the lug (120) on the busbar (105) to secure the busbar (105) on the busbar terminal (110). More specifically, the projections (124A, 124B) are configured to have a spring back effect that helps improve the contact pressure between the busbar (105) and the busbar terminal (110), by generating tension in the busbar contact region. This contact pressure is equal to or is greater than the contact pressure generated by a conventional fastener. The snap-fit joint (122) further ensures a positive lock for fastening the busbar (105) and busbar terminal (110) at a predetermined pressure, while also resolving typical hardware torque loss problem observed in conventional fasteners based mounting and unmounting.
The locking means also has a provision for dismantling the cover (115) from the busbar (105) and the busbar terminal (110). More specifically, the lug (120) has a hole (126) configured along an operative longitudinal axis thereof. A pulling tool (10) is received in the hole (126) to travel till the operative end of the snap-fit joint (122). The handles of the pulling tool (10) clamp themselves against the snap-fit joint (122) and pulls back the joint to facilitate detachment of the cover (115) from the busbar (105).
In accordance with a second embodiment, the locking means includes a tree clip fastener (130) extendably configured on the cover (115). The tree clip fastener (130) is configured to be received in the second recess (112) through the first recess (107). In another embodiment, the locking means further includes a nut (132) configured to be received in the second recess (112). The nut (132) is configured to fastenably receive the tree clip fastener (130) to facilitate attachment of the busbar (105) with the busbar terminal (110). The tree clip fastener (130) facilitates positive locking onto the weld nut threads while pushing against the washer spring force to create a permanent joint between the busbar (105) and the busbar terminal (110).
In yet another embodiment, the nut (132) is weldably attached in the second recess (112).
In still another embodiment, the locking means includes a spring washer (134) configured to be disposed on the tree clip fastener (130). The spring washer (134) is configured to maintain a contact force of the lug (120) on the busbar (105) to secure the busbar (105) on the busbar terminal (110). More specifically, the spring washer (134) is configured to pull back, when the cover (115) is pressed on the busbar (105), to create a predetermined force between the busbar (105) and the busbar terminal (110), thereby ensuring the required contact pressure at the contact points. This contact pressure is equal or greater to contact pressure generated by bolt or screw.
In one embodiment, the tree clip fastener (130) is of a polymeric material.
In a further embodiment, the spring washer (134) is a wavy spring washer.
In an embodiment, the cover (115) is of an insulating material.
In one embodiment, the cover (115) includes a plurality of retention latches (125) configured along an operative periphery thereof. Each latch (125) is configured to be clamped along the length of the busbar (105).
Both embodiments of the present disclosure ensures that hardware such as fasteners are not lost or misplaced during assembly. Further, the embodiments eliminate torque loss that is observed in conventional hardware fitments. As a result, there is no element that will come loose during usage of the battery pack, nor will there be any gap formation between the busbar (105), the cover (115) and the terminals, thereby protecting the busbar connection from water ingress due to condensation in case of top cooling system of the battery pack. Also, any possibility of short circuit that may be caused due to water ingress is eliminated, while the creepage and clearance distance between the busbar (105), the cover (115) and the terminals are improved. All these advantages help in saving manufacturing and maintenance cost, and reduces the overall weight by eliminating hardware like screws and bolts.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS
The present disclosure described hereinabove has several technical advantages including, but not limited to, a mounting arrangement for a busbar assembly of a battery pack that:
• eliminates torque loss caused due to fastening and unfastening of bolts;
• protects the busbar connection from water ingress due to condensation in the battery pack;
• reduces manufacturing and maintenance cost of the battery pack; and
• relatively reduces the overall weight by eliminating hardware like screws and bolts.
The foregoing disclosure has been described with reference to the accompanying embodiments which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Any discussion of devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application. While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. , Claims:WE CLAIM:
1. A mounting arrangement (100) for a busbar assembly of a battery pack, said arrangement (100) comprising:
• a busbar (105) having at least one first recess (107) configured thereon;
• at least one busbar terminal (110) configured to receive said busbar (105) thereon, said busbar terminal (110) having at least one second recess (112) configured thereon complementary to said first recess (107);
• a cover (115) configured to be disposed on said busbar (105); and
• at least one locking means configured on said cover (115) complementary to said first recess (107), said locking means configured to be received in said first recess (107) and said second recess (112) to enable secure attachment of said busbar (105) with said busbar terminal (110).
2. The arrangement (100) as claimed in claim 1, wherein said locking means includes a lug (120) configured to extend from said cover (115), said lug (120) having an annular snap-fit joint (122) configured at an operative free end thereof, said lug (120) configured to be received in said first recess (107) and said second recess (112), when said cover (115) is pressed against said busbar (105), to enable interlocking of said snap-fit joint (122) in said second recess (112).
3. The arrangement (100) as claimed in claim 2, wherein said locking means includes a pair of projections (124A, 124B) configured on said cover (115), on opposite sides of said lug (120), said projections (124A, 124B) being configured to maintain a contact force of said lug (120) on said busbar (105) to secure said busbar (105) on said busbar terminal (110).
4. The arrangement (100) as claimed in claim 2, wherein said lug (120) has a hole (126) configured along an operative longitudinal axis thereof, to receive a pulling tool (10) to facilitate detachment of said cover (115) from said busbar (105).
5. The arrangement (100) as claimed in claim 2, wherein said lug (120) is of a polymeric material.
6. The arrangement (100) as claimed in claim 1, wherein said locking means includes a tree clip fastener (130) extendably configured on said cover (115), said tree clip fastener (130) being configured to be received in second recess (112) through said first recess (107).
7. The arrangement (100) as claimed in claim 6, wherein said locking means includes a nut (132) configured to be received in said second recess (112), said nut (132) being configured to fastenably receive said tree clip fastener (130) to facilitate attachment of said busbar (105) with said busbar terminal (110).
8. The arrangement (100) as claimed in claim 7, wherein said nut (132) is weldably attached in said second recess (112).
9. The arrangement (100) as claimed in claim 6, wherein said locking means includes a spring washer (134) configured to be disposed on said tree clip fastener (130), said spring washer (134) being configured to maintain a contact force of said lug (120) on said busbar (105) to secure said busbar (105) on said busbar terminal (110).
10. The arrangement (100) as claimed in claim 6, wherein said tree clip fastener (130) is of a polymeric material.
11. The arrangement (100) as claimed in claim 9, wherein said spring washer (134) is a wavy spring washer.
12. The arrangement (100) as claimed in claim 1, wherein said cover (115) is of an insulating material.
13. The arrangement (100) as claimed in claim 1, wherein said cover (115) includes a plurality of retention latches (125) configured along an operative periphery thereof, each latch (125) being configured to be clamped along the length of said busbar (105).

Dated this 9th day of May, 2024

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
OF R. K. DEWAN & CO.
AUTHORIZED AGENT OF APPLICANT

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT CHENNAI