Battery Module Bus-Bar Holder Elastic Support
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Solution Overview
Problem
Existing battery modules face challenges in varying shapes to match diverse device exteriors while ensuring safety, particularly in high-power applications like electric vehicles, where traditional structures may not adequately support bus-bars or prevent stress and movement issues.
Innovation Solution
A battery module design featuring bus-bars with bent connecting portions and a holder with support portions to align and secure the bus-bars, reducing stress and facilitating easy connection, while an extending portion allows for real-time voltage and SOC monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional rigid structures are used to support bus-bars, then structural strength is improved, but stress concentration and movement restrictions occur
Solution Approach 1:
The support portion changes its physical state from rigid to elastic, allowing it to deform under stress. This parameter change enables the support to absorb stress fluctuations and accommodate bus-bar movement while maintaining support functionality, thereby reducing stress concentration and improving reliability
Solution Approach 2:
The elastic support portion acts as a pre-configured cushioning element that absorbs stress before it can concentrate on the bus-bar or surrounding structures. By providing this elastic cushioning in advance, the system prevents stress concentration and potential failure points
2Reliability
If bus-bars are rigidly fixed to terminal portions, then electrical connectivity is improved, but stress transmission to terminal portions increases
Solution Approach 1:
The elastic support portion serves as an intermediary element between the bus-bar and the terminal portion. It maintains the necessary electrical connectivity while simultaneously acting as a stress buffer that prevents stress transmission from the bus-bar to the terminal portion, thereby protecting the terminal from stress-related damage
Solution Approach 2:
The elastic support portion provides pre-configured stress cushioning at the connection point between the bus-bar and terminal portion. This cushioning mechanism is built into the structure beforehand, allowing it to absorb stress fluctuations before they can reach and damage the terminal portion
3Stability of the object's composition
If bus-bar holder structure is added to support bus-bars, then bus-bar stability is improved, but device complexity increases
Solution Approach 1:
The bus-bar holder structure is designed to perform multiple functions simultaneously: it provides mechanical support for the bus-bar, positions the elastic support portion at the correct location, and maintains the overall structural integrity of the battery module. This multi-functionality reduces the need for additional separate components, thereby managing complexity while achieving stability
Data Source
AI summary
A battery module includes a plurality of battery cells aligned in one direction, each battery cell of the plurality of battery cells including a terminal portion on a first surface of a respective battery cell, a bus-bar electrically connect between the terminal portions of the plurality of battery cells, and a bus-bar holder positioned on the first surfaces of the plurality of battery cells, the bus-bar holder including support portions configured to support two different surfaces of the bus-bar, respectively.