Integrated Bus Bar Assembly for Battery Module Lead Connection
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Solution Overview
Problem
Conventional battery modules require individual assembly of bus bars, bus bar frames, and sensing bus bars, leading to increased assembly time, manufacturing costs, and potential for erroneous assembly.
Innovation Solution
A bus bar unit that integrally connects electrode leads of battery cells, comprising a first and second bus bar frame, bus bars, and a sensing bus bar with an elastic bending portion, allowing for sliding assembly and voltage sensing, along with a reinforcing plate to cover the battery cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If bus bars, bus bar frames, and sensing bus bars are individually assembled, then each component can be separately manufactured and replaced, but assembly time increases and manufacturing cost increases
Solution Approach 1:
The patent combines multiple separate components (bus bars, bus bar frames, and sensing bus bars) into a single integrated bus bar unit. This integration eliminates the need for individual assembly steps, thereby improving assembly efficiency while maintaining manufacturing flexibility through modular design of the entire unit.
Solution Approach 2:
The integrated bus bar unit performs multiple functions simultaneously: it provides electrical connection through bus bars, structural support through bus bar frames, and voltage sensing through integrated sensing bus bars. This multi-functionality reduces the number of separate components needed while maintaining all necessary capabilities.
2Ease of manufacture
If bus bars, bus bar frames, and sensing bus bars are individually assembled, then each component can be independently manufactured, but the number of molds and packaging required increases manufacturing cost
Solution Approach 1:
The patent merges multiple independent components into a single integrated bus bar unit, reducing the total number of components from three separate items to one unified structure. This simplification reduces the number of molds and packaging requirements while maintaining manufacturing capability.
3Ease of operation
If components are individually assembled, then assembly flexibility is maintained, but erroneous assembly may occur and assembly time increases
Solution Approach 1:
By integrating bus bars, bus bar frames, and sensing bus bars into a single pre-assembled unit, the patent eliminates the risk of erroneous assembly that occurs when multiple components are individually installed. The integrated unit ensures correct positioning and connection while maintaining operational flexibility.
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
Enhances assembly efficiency by reducing assembly time and costs, minimizing errors, and improving manufacturing precision.
Implementation Method 1
a sensing bus bar with an elastic bending portion, allowing for sliding assembly and voltage sensing
Data Source
AI summary
Disclosed is a battery module, which includes a plurality of battery cells stacked one another and respectively having electrode leads protruding in the front and rear directions of the battery module, and a bus bar unit configured to integrally connect the electrode leads of the plurality of battery cells.