Battery Module Bus-Bar Assembly With Insulating Rivets
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Solution Overview
Problem
Existing battery systems face risks of short circuits due to metal screw negligence or soldering issues, which can lead to hazards when batteries are overloaded and cannot be disconnected in time.
Innovation Solution
A battery module design featuring bus-bars with hooking portions and insulating rivets, along with wire-bonding technology for connections, reduces short circuit risks and enhances open circuit safety by using insulating rivets and wire-bonding as safety protection mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If metal screw locking way is used for fixing and joining batteries, then the battery system can be assembled, but a short circuit risk may be caused by artificial negligence of metal screws or falling metal screws
Solution Approach 1:
The patent introduces an insulating rivet as an intermediary component between the metal screw and the battery terminals. This insulating rivet prevents direct metal-to-metal contact, thereby eliminating the short circuit risk while maintaining the mechanical fastening function. The insulating rivet acts as a mediator that preserves the beneficial mechanical connection while blocking the harmful electrical conduction path.
Solution Approach 2:
The patent employs a consumable fuse wire as a safety mechanism that is designed to fail deliberately under overload conditions. This fuse wire is a low-cost, single-use component that sacrifices itself to protect the expensive battery system from damage due to overcurrent, embodying the principle of using cheap disposable objects to protect valuable systems.
2Ease of manufacture
If soldering technology is used for connecting batteries, then the batteries can be connected, but if the battery is overloaded it is unable to be disconnected in time, consequently various hazards are caused
Solution Approach 1:
The patent transforms the static soldered connection into a dynamic system by introducing a fuse wire that can change its state from conducting to non-conducting based on current conditions. This dynamic element allows the connection to automatically disconnect when overloaded, providing time-dependent safety protection while maintaining reliable connection under normal operating conditions.
Solution Approach 2:
The fuse wire is pre-installed in series with the battery connection, creating a preliminary protective measure against potential overload hazards. This pre-positioned safety device is designed to fail in a controlled manner before the overload can cause damage to the battery system, embodying the principle of preliminary anti-action by preparing a counter-measure in advance.
3Ease of manufacture
If traditional fixing methods are used, then the battery system can be assembled, but the open circuit safety is insufficient
Solution Approach 1:
The patent segments the electrical connection path by introducing a detachable fuse wire component separate from the main battery terminals and bus bars. This segmentation allows the safety function to be independently designed and installed, enabling the assembly process to proceed with standard components while adding the safety feature as a separate element that can be easily integrated into the existing assembly workflow.
Data Source
AI summary
A battery module includes a plurality of batteries, an upper cover covered on the plurality of the batteries, a plurality of bus-bars, a plurality of detection lines, a plurality of insulating rivets, and a plurality of wirings connected between the plurality of the batteries and the plurality of the bus-bars. A top of the upper cover has a plurality of first mounting areas. Each first mounting area has a mounting portion and two location holes. Each bus-bar is disposed on the mounting portion of one first mounting area. Each bus-bar has a main portion. The main portion has two hooking portions and a plurality of fastening holes. The two hooking portions are inserted into the two location holes. One ends of the plurality of the detection lines are fastened to the plurality of the fastening holes by the plurality of the insulating rivets.