Battery Cartridge-Connecting System With Welded Bus Bars
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Solution Overview
Problem
Existing battery module systems face challenges in achieving stable electrical connections and mechanical coupling in compact structures, leading to potential short circuits and reduced mechanical strength, which can result in overheating and safety issues, especially in high-capacity battery systems used in vehicles.
Innovation Solution
A battery cartridge-connecting system comprising bus bars with plate-shaped bodies, coupling parts, and electrical connection parts, a base plate with openings for secure mounting, and a printed circuit board with connection holes, allowing for easy mechanical and electrical coupling while preventing short circuits through skirt and groove engagement and secure welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If elastic members such as springs are used to accomplish electrical connection in a contact fashion, then the electrical connection can be achieved in a compact structure, but the mechanical strength and resistance to vibrations are low and contact resistance increases due to corrosion
Solution Approach 1:
The patent replaces the mechanical spring-based contact system with a welding-based electrical connection system. The bus bar is welded directly to the electrode terminals, eliminating the need for elastic members and their associated mechanical contact interfaces. This substitution resolves the contradiction by providing both compact structure and high reliability through direct metallurgical bonding that resists corrosion and vibration.
Solution Approach 2:
The patent merges the electrical connection function and mechanical support function into a single integrated welding joint between the bus bar and electrode terminals. Instead of using separate components (springs for contact, additional structures for mechanical support), the welding process combines both functions into one reliable connection, achieving compact structure while maintaining high electrical and mechanical reliability.
2Strength
If welding or bolts and nuts are used to accomplish mechanical coupling, then the mechanical strength is high, but it is difficult to accomplish in a compact structure with small space
Solution Approach 1:
The patent combines mechanical coupling and electrical connection into a single welding operation. The bus bar serves both as the electrical conductor and the mechanical coupling element, eliminating the need for separate mechanical fasteners like bolts and nuts. This integration achieves high mechanical strength through the welding joint while maintaining a compact structure by removing redundant components.
Solution Approach 2:
The patent extracts the mechanical fastening function from the electrical connection system by using the bus bar itself as the coupling element. Instead of adding separate mechanical components (bolts, nuts, brackets) to achieve mechanical strength, the design extracts only the essential electrical connection function and uses welding to provide both electrical and mechanical integrity in a compact form.
3Object-affected harmful factors
If a closed structure battery module is used to prevent electrolyte leakage, then safety against leakage is improved, but heat generated in unit cells is accumulated and accelerates deterioration
Solution Approach 1:
The patent applies local quality by providing selective ventilation only at specific locations where heat dissipation is needed, rather than creating a fully open structure that would compromise electrolyte containment. The bus bar design includes localized ventilation channels or gaps that allow heat to escape from critical areas while maintaining the overall closed structure for electrolyte safety.
Data Source
AI summary
A battery cartridge-connecting system for battery modules including bus bars, each of which includes a plate-shaped bar body, coupling parts, and electrical connection parts; a base plate, to which the bus bars are easily mounted; and a printed circuit board (PCB), which is easily coupled to the bus bars and is mounted to the base plate in a compact structure. The present invention also provides a battery module and a medium- or large-sized battery system including the battery cartridge-connecting system.