Asymmetric Battery Cell Terminals for Bus Bar Short Prevention
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Solution Overview
Problem
Existing battery modules face challenges in preventing electrical shorts during the fastening of bus bars to electrode terminals, particularly in high-capacity configurations like those for electric and hybrid cars, where compact designs are essential but shorts can occur due to close terminal alignment.
Innovation Solution
The battery module design features battery cells with electrode terminals spaced different distances from the center of each cell, allowing bus bars to be fastened diagonally, thereby increasing the distance between adjacent terminals and preventing shorts while maintaining a compact form factor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery cells are arranged in a compact configuration to increase capacity, then the battery module achieves higher output and capacity, but the distance between adjacent electrode terminals decreases, increasing the risk of electrical shorts during bus bar fastening
Solution Approach 1:
The patent applies asymmetry by configuring electrode terminals at different distances from the center of each battery cell. Specifically, one electrode terminal is positioned at a first distance from the center while the other is positioned at a second distance, creating an asymmetric arrangement that increases the spacing between adjacent terminals in the battery module, thereby preventing electrical shorts during bus bar fastening operations
2Volume of moving object
If electrode terminals are positioned closer together to reduce cell size, then the battery cell becomes more compact, but the risk of terminal contact errors increases during assembly
Solution Approach 1:
The asymmetric positioning of electrode terminals creates a distinctive pattern that makes correct alignment visually apparent during assembly. By positioning terminals at different distances from the cell center, the design provides an intuitive guide for proper bus bar installation, reducing the risk of terminal contact errors while maintaining compact cell dimensions
3Ease of operation
If bus bars are fastened in a straight line configuration, then the assembly process is simplified, but adjacent terminals may come into contact causing electrical shorts
Solution Approach 1:
The patent resolves the contradiction by transitioning from a one-dimensional linear arrangement to a two-dimensional asymmetric configuration. The electrode terminals are positioned at different distances from the cell center, creating an offset pattern that naturally prevents contact between adjacent terminals during straight-line fastening operations, thus maintaining operational simplicity while ensuring reliability
Data Source
AI summary
A battery module may include a plurality of battery cells aligned in one direction, each of the plurality of battery cells including: a first electrode terminal and a second electrode terminal, a bus bar for electrically connecting the plurality of battery cells, the bus bar being fastened to the first electrode terminal or the second electrode terminal of any one of the plurality of battery cells, and the first electrode terminal or the second electrode terminal of an adjacent one of the plurality of battery cells, and a housing accommodating the plurality of battery cells electrically connected by the bus bar. The first electrode terminal and the second electrode terminal of adjacent battery cells may be spaced differently, for example, a battery cell may have first and second electrode terminals spaced at different distances from a center of a top side of the respective battery cell.