Rechargeable Battery Module Multi-Directional Bus Bar Contact
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Solution Overview
Problem
Rechargeable battery modules experience reduced lifespan and potential shutdown due to high contact resistance and heat generation at the interface between electrode terminals and bus bars, leading to deteriorated performance.
Innovation Solution
The rechargeable battery module design includes a bus bar with a first concave groove and a protruding portion, and a plate terminal with a second concave groove and protruding portion, allowing for multiple-directional surface contact with a bolt terminal, which reduces contact resistance and heat generation by increasing the contact area and utilizing cooling fins for heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrode terminals and bus bar make simple contact, then device complexity is reduced, but contact resistance increases and heat generation worsens
Solution Approach 1:
The contact structure transitions from simple point or line contact to multi-directional surface contact. The bus bar and electrode terminal are configured to contact each other in multiple directions (vertical, horizontal, and diagonal), effectively utilizing three-dimensional space to maximize contact area and reduce contact resistance.
Solution Approach 2:
The contact interface is divided into multiple contact regions through the configuration of protruding portions and recessed portions. Instead of a single large contact surface, the structure creates multiple discrete contact points that collectively provide extensive contact area while maintaining structural simplicity.
2Reliability
If contact area between electrode terminal and bus bar is increased, then contact resistance decreases, but manufacturing precision requirements increase
Solution Approach 1:
The bus bar and electrode terminal feature asymmetric protruding and recessed portions that guide the assembly process. The protruding portion of the bus bar fits into the recessed portion of the electrode terminal, creating a self-aligning mechanism that reduces the precision requirements for manual assembly while ensuring consistent multi-directional contact.
Solution Approach 2:
The protruding and recessed portions are pre-formed during manufacturing, creating a built-in alignment feature. This preliminary structural preparation ensures that during assembly, the components naturally align to achieve optimal multi-directional contact without requiring high-precision positioning operations.
3Duration of action of stationary object
If traditional contact structure is used, then device complexity is low, but lifespan deteriorates due to heat generation
Solution Approach 1:
The structure converts the potential harm of heat generation into a benefit by designing features that actively manage thermal effects. The multi-directional contact configuration and protruding/recessed portions not only reduce contact resistance but also create pathways for heat dissipation, turning the heat problem into an opportunity for improved thermal management.
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 configuration effectively decreases contact resistance and heat generation at the interface, enhancing the lifespan and operational reliability of the rechargeable battery module by maximizing contact area and improving heat dissipation.
Implementation Method 1
Contact resistance is formed between the electrode terminal and the bus bar that contact each other
Implementation Method 2
the contact resistance generates heat (e.g., resistive heating due to electrical current flowing through contact resistance at the contact location)
Implementation Method 3
utilizing cooling fins for heat dissipation
Data Source
AI summary
A rechargeable battery module includes a plurality of unit battery cells and a bus bar interconnecting a first electrode terminal of a first unit battery cell of the unit battery cells and a second electrode terminal of a second unit battery cell of the unit battery cells, the first electrode terminal having a first plurality of surfaces, the second electrode terminal having a second plurality of surfaces, and the bus bar having a third plurality of surfaces, the first plurality of surfaces being configured to face and make surface contact with corresponding ones of the third plurality of surfaces, the second plurality of surfaces being configured to face and make surface contact with corresponding ones of the third plurality of surfaces, and the first, second, and third pluralities of surfaces facing along a plurality of directions.