Insulating Cover for Battery Module Bus Bar Short Circuit Prevention
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Solution Overview
Problem
There is a risk of short circuits occurring between conductive members and connection bus bars in battery modules and electronic devices due to the lack of insulation in existing connection systems.
Innovation Solution
A connection apparatus featuring a connection bus bar with an insulating cover made of synthetic resin, which is attached to the lower face of the bus bar to prevent short circuits, and adjustable insulating covers of varying lengths to accommodate different distances between the battery module and electronic device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a connection bus bar is arranged to connect battery module and electronic device, then electrical connection is achieved, but risk of short circuit increases due to lack of insulation
Solution Approach 1:
An insulating cover made of synthetic resin is introduced as an intermediary component between the connection bus bar and the conductive member below it. This insulating cover prevents direct contact between conductive parts, thereby eliminating the short circuit risk while maintaining the electrical connection function of the bus bar.
Solution Approach 2:
The connection apparatus is segmented into distinct functional components: the connection bus bar for electrical connection, the insulating cover for isolation, and the conductive member for additional connectivity. This segmentation allows each component to perform its specific function without interfering with others, particularly preventing unwanted electrical contact between the bus bar and conductive member.
2Adaptability or versatility
If insulating cover is made from extruded material and cut to length, then manufacturing flexibility and adaptability improve, but manufacturing process complexity increases
Solution Approach 1:
Instead of creating different insulating covers for different lengths, the invention uses a single extruded insulating cover material where the length parameter is varied by cutting. This allows the same base component to adapt to different connection distances between battery modules and electronic devices, providing versatility without requiring multiple design variants.
Solution Approach 2:
The insulating cover is designed as a universal component that can be cut to any required length to accommodate different installation scenarios. This single universal design replaces the need for multiple specialized covers, simplifying inventory management and manufacturing while maintaining adaptability to various connection geometries.
Data Source
AI summary
A connection apparatus for connecting a battery module and an electronic device is for connecting a battery module in which a plurality of electric cells are arranged in a line and are connected to each other, and an electronic device arranged on a side of the battery module. The connection apparatus includes: a connection bus bar in which a welding plate to be connected to a connection electrode in the battery module is provided at one end, and the other end portion to be connected to a connecting portion of the electronic device is provided at the other end; and an insulating cover that is made of a synthetic resin and is attached to a lower face of the connection bus bar.