Battery Module Power Bus Connection With Particle-Blocking Mounting Aid
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Solution Overview
Problem
Existing methods for forming connections between power buses in battery modules are not reliable, as they can allow particles to enter the housing and cause electrical issues such as short circuits, and may result in the connecting element falling inside the module, rendering it unusable.
Innovation Solution
A method involving a mounting aid with a connecting element, such as a screwing element, that forms a mechanical connection between the first and second power buses through an opening in the housing, ensuring full surface contact to prevent particle entry and using a cap nut or thread to secure the connection, allowing for reliable electrical conductivity while compensating for tolerances and preventing damage to other connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connection methods are used between power buses, then assembly is simple, but particles can enter the housing and cause short circuits
Solution Approach 1:
The mounting aid serves as an intermediary tool that facilitates the connection process between power buses. It provides a controlled environment for forming the electrical connection, preventing particles from entering the housing while enabling the assembly process to proceed systematically through the opening in the housing.
Solution Approach 2:
The mounting aid is inserted into the opening before the actual connection is formed. This preliminary positioning establishes a protective barrier and defines the connection path, ensuring that particles generated during the connection process cannot enter the housing interior, thus preventing short circuits before they can occur.
2Reliability
If conventional connection methods are used, then assembly is straightforward, but the connecting element may fall inside the module
Solution Approach 1:
The mounting aid acts as a mediator that guides and contains the connecting element during the assembly process. By providing a structured pathway and support structure, it prevents the connecting element from falling into the housing interior while still allowing straightforward assembly operations to be performed through the opening.
Solution Approach 2:
The mounting aid is positioned in advance to establish a secure pathway for the connecting element. This preliminary setup ensures that the connecting element remains contained and guided throughout the assembly process, preventing it from falling inside the module while maintaining ease of operation.
3Reliability
If a mechanical connection is formed through the opening, then electrical conductivity is achieved, but particles may contaminate the interior
Solution Approach 1:
The mounting aid is inserted into the opening before the mechanical connection is formed. This preliminary positioning creates a protective barrier that defines the connection pathway, ensuring that particles generated during the connection process remain contained within the mounting aid and cannot enter the housing interior, thus preventing contamination while enabling reliable electrical connection.
Solution Approach 2:
The mounting aid serves as an intermediary structure between the external connection environment and the protected housing interior. It provides a controlled interface for forming the mechanical and electrical connection between power buses, filtering out particles and preventing them from contaminating the interior space while maintaining electrical conductivity.
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
This method ensures a reliable and secure electrical connection between the power buses, preventing particle entry and potential short circuits, while allowing for easy assembly and disassembly, and maintaining the integrity of other electrical connections.
Implementation Method 1
the mounting aid resting against the first power bus and/or the second power bus. This has the advantage that it can prevent or at least reduce the possibility of particles that emerge during the connection process from entering an interior of the housing of the battery module
Implementation Method 2
the first power bus is connectable or connected to the voltage tap of the terminally arranged battery cell of the plurality of battery cells, particularly preferably by means of laser welding in a material-locking manner
Data Source
AI summary
A method for forming an electrically conductively formed connection between a first power bus, which is electrically conductively connectable or connected to a voltage tap of a terminally arranged battery cell of a plurality of electrically conductively interconnected battery cells, and a second power bus, which is electrically conductively connected to a control unit of a battery module. The plurality of battery cells, the control unit, and the first power bus and the second power bus are accommodated in a housing of the battery module. An opening is provided in the housing, and an assembly aid is inserted into the opening. A connecting element is accommodated in the mounting aid, and a mechanical connection is formed between the first power bus and the second power bus by the connecting element, such that an electrically conductively formed connection is formed between the first power bus and the second power bus.