Battery Module Bus Bar Cover Insulation Design
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Solution Overview
Problem
Battery modules face safety accidents and malfunctions due to short circuits caused by high-voltage current flowing through uninsulated bus bars, which can come into contact with foreign substances or internal structures.
Innovation Solution
A bus bar cover is designed to insulate the end portions of the bus bar, featuring a hollow portion that extends away from the bus bar to prevent exposure and potential short circuits, while also including insulating walls and latching protrusions to ensure secure contact and prevent electrical interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bus bar is exposed to enable electrical connection, then electrical connectivity is improved, but safety and insulation are worsened due to potential contact with foreign substances or internal structures
Solution Approach 1:
The patent introduces a bus bar cover as an intermediary component that physically separates the conductive bus bar from the external environment. The cover includes a through-hole that allows electrical connection while the surrounding cover structure acts as an insulating barrier, preventing direct contact between the bus bar and foreign substances or internal structures, thus resolving the contradiction between electrical connectivity and short circuit prevention
Solution Approach 2:
The bus bar cover applies local quality by providing insulation only in specific areas where it is needed. The through-hole region maintains electrical connectivity while the surrounding cover material provides localized insulation. This selective application of insulating properties allows the bus bar to be electrically accessible where needed while protected from harmful contact in other areas
2Object-affected harmful factors
If the bus bar is fully insulated to prevent short circuits, then safety is improved, but electrical connectivity is worsened due to inability to make proper contact
Solution Approach 1:
The bus bar cover is segmented into distinct functional zones: a through-hole portion that exposes the bus bar for electrical connection and a surrounding cover portion that provides insulation. This segmentation allows the single component to simultaneously fulfill both electrical connectivity and short circuit prevention functions by dividing the structure into regions with different properties
Solution Approach 2:
The bus bar cover serves as a mediator that reconciles the conflicting requirements of insulation and electrical connection. The through-hole acts as an intermediary aperture that allows electrical contact while the surrounding cover material maintains the insulating barrier, enabling both functions to coexist without compromising either safety or connectivity
Data Source
AI summary
Provided is a battery module. The battery module includes: a plurality of battery packs; a bus bar electrically connecting neighboring battery packs to each other; and a bus bar cover covering an end portion of the bus bar for insulating the bus bar, the bus bar cover including a hollow portion through which a coupling hole of the bus bar is exposed, the hollow portion extending in a direction away from the bus bar. According to embodiments, in the battery module, the bus bar electrically connecting different battery packs is sufficiently insulated to prevent malfunctions and safety accidents caused by a short circuit of the bus bar through which charging and discharging high-voltage current flows.