Battery Module Bus Bar With Elastic Insulating Guide
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Solution Overview
Problem
Existing battery module assembly processes are inefficient due to the need for multiple bus bar and tightening member installations, and they fail to accommodate manufacturing tolerances and volume changes in unit batteries, leading to assembly quality deterioration and deformation.
Innovation Solution
A battery module design featuring improved bus bars with through-holes and an insulating guide made of elastic material, including holder units and narrow width portions with bending grooves, which supports bus bars and allows for easy assembly and accommodation of manufacturing tolerances and volume changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate bus bars and tightening members are used to connect unit batteries, then reliable electrical connection is achieved, but assembly time increases due to multiple assembly processes
Solution Approach 1:
The bus bar and tightening member are merged into a single integrated connection member. The connection member includes a bus bar portion for electrical connection and a tightening portion with an elastic body that provides clamping force, eliminating the need for separate components and reducing assembly steps.
Solution Approach 2:
The connection member serves multiple functions simultaneously: it provides electrical connection through the bus bar portion, mechanical fastening through the tightening portion, and adaptive clamping through the elastic body that accommodates manufacturing tolerances and volume changes of unit batteries.
2Stability of the object's composition
If rigid connection members are used to connect unit batteries, then structural stability is improved, but manufacturing tolerances and volume changes cause assembly quality deterioration and battery deformation
Solution Approach 1:
The connection member transitions from a rigid structure to a dynamic, adaptive structure. The elastic body in the tightening portion can deform and adjust its clamping force, allowing the connection member to adapt to manufacturing tolerances and volume changes of unit batteries during charging and discharging cycles.
Solution Approach 2:
The elastic modulus and geometric parameters of the elastic body are optimized to provide appropriate compliance. The elastic body can undergo controlled deformation within a specific range, absorbing dimensional variations while maintaining sufficient clamping force for reliable connection.
3Reliability
If multiple separate components are used for connection, then connection reliability is improved, but device complexity increases
Solution Approach 1:
Multiple separate components (bus bar and tightening member) are merged into a single integrated connection member, reducing the number of parts while maintaining all necessary functions for reliable electrical connection and mechanical fastening.
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
The design reduces assembly time, enhances assembly quality, and prevents unit battery deformation by ensuring correct bus bar positioning and accommodating volume changes during charging and discharging.
Implementation Method 1
the insulating guide is made of an elastic insulating material such that the manufacturing tolerance and the volume change of the unit battery that is generated in the charging and discharging process of the unit battery may be easily accommodated
Implementation Method 2
Each narrow width portion may include a pair of bending grooves formed on two opposite sides of the corresponding narrow width portion
Data Source
Figure 1
Figure 2
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AI summary
A battery module of the present invention includes a plurality of unit batteries and a connection member electrically connecting the plurality of unit batteries. The connection member includes: a plurality of bus bars, each of the plurality of bus bar having two through-holes respectively corresponding to two electrode terminals protruding from two adjacent unit batteries of the plurality of unit batteries; and an insulating guide having a plurality of holder units configured to support the plurality of bus bars, and a plurality of narrow width portions positioned between the plurality of holder units and connecting the plurality of holder units along a first direction.