Battery Module Bus Bar Assembly for Configurable Cell Connections
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Solution Overview
Problem
Existing rechargeable battery modules are designed for specific voltage and current requirements, leading to increased development and production costs when custom designs are needed for different applications.
Innovation Solution
A rechargeable battery module design that includes multiple battery cells connected through bus bars and bonding wires, allowing for various voltage and current configurations using a single design, with bus bars fixed to a holder case using double-sided adhesive tape or insert molding, enabling flexible serial and parallel connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate module designs are developed for different voltage and current requirements, then specific customer applications are met, but development and production costs increase
Solution Approach 1:
The battery module employs a universal holder case design with standardized bus bar positions and connection structures that can accommodate different battery cell configurations. The same holder case can support various series and parallel connections by simply rearranging the battery cells and adjusting the bus bar connections, eliminating the need for separate module designs for different voltage and current requirements.
Solution Approach 2:
The module design segments the connection structure into standardized components: the holder case provides a fixed framework, bus bars serve as universal connection elements, and bonding wires enable flexible cell-to-bus bar connections. This segmentation allows independent configuration of battery cells while maintaining a consistent overall structure, reducing design complexity for different applications.
2Adaptability or versatility
If separate module designs are developed for different voltage and current requirements, then specific customer applications are met, but production costs increase
Solution Approach 1:
The holder case is designed as a universal component with standardized features including bus bar mounting positions, battery cell accommodation spaces, and connection terminals. This universal design allows the same holder case to be used across multiple module configurations, significantly reducing tooling costs, inventory requirements, and assembly fixture complexity for different voltage and current specifications.
Solution Approach 2:
The module configuration is adjusted by changing parameters such as the number of battery cells, their arrangement pattern, and bus bar connection points rather than redesigning the entire module. This parameter-based configuration approach maintains manufacturing simplicity while achieving different voltage and current outputs, thereby reducing production costs.
3Ease of manufacture
If battery cells are connected through tabs before fastening holders, then connection is achieved, but design flexibility for different configurations is limited
Solution Approach 1:
The bus bars serve as intermediary connection elements between battery cells, replacing direct tab-to-tab connections. The bus bars are mounted on the holder case before battery cell installation, providing standardized connection points that facilitate both simple assembly and flexible configuration. This intermediary structure allows easy reconfiguration by simply changing which battery cells connect to which bus bar positions.
Data Source
AI summary
A rechargeable battery module includes: a plurality of battery cells; a lower case accommodating lower ends of the battery cells; a holder case coupled to the lower case and accommodating the battery cells; a plurality of bus bars on the holder case; a plurality of bonding wires connecting the battery cells to the bus bars; and an upper case covering the bus bars and the bonding wires and coupled to the holder case.