Battery Module Bus Bar Holder Vibration and Heat Management
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Solution Overview
Problem
Rechargeable battery modules for high-capacity electric vehicles face instability due to high heat-generated current concentration at bus bar connections and vibrations affecting the connecting structure of unit cells, leading to potential weakness in the bus bar's connecting mechanism.
Innovation Solution
A rechargeable battery module design featuring a bus bar holder with a protrusion and cutouts, made from aluminum and copper materials, which includes an ultrasonic welding connection to a power cable, providing enhanced mechanical and electrical stability through a sub-assembly formation that absorbs vibrations and disperses stress effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bus bar is used to connect unit cells and power cable, then electrical connection is achieved, but high heat is generated due to current concentration causing connection melting and instability
Solution Approach 1:
The bus bar connection structure is segmented into multiple contact points through protrusions and cutouts, distributing the current flow across several areas rather than concentrating it at a single point, thereby reducing heat generation at any one location
Solution Approach 2:
The bus bar holder with protrusions and cutouts is pre-formed to create an optimized connection geometry before assembly, ensuring that current is distributed evenly from the beginning of operation and preventing heat concentration issues
2Reliability
If unit cells are arranged in a row and connected with bus bar, then electrical connection is established, but vibration in x-axis and z-axis directions causes weakness in connecting structure
Solution Approach 1:
The bus bar holder design incorporates vibration-absorbing features and stress-dispersing geometries in advance, cushioning the connecting structure against vibrations before they can cause damage to the bus bar connections
Solution Approach 2:
The connection structure utilizes composite design elements combining rigid bus bar materials with vibration-absorbing holder materials, creating a system that maintains electrical conductivity while resisting mechanical vibration effects
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 achieves stable electrical and mechanical connections between unit cells and a power cable, effectively managing vibrations and heat-related issues, thereby enhancing the overall stability and performance of the rechargeable battery module.
Implementation Method 1
an ultrasonic welding connection to a power cable
Data Source
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AI summary
A rechargeable battery module includes: a plurality of unit cells arranged along a first direction; a bus bar holder on the unit cells; a bus bar in the bus bar holder electrically connecting the unit cells; first and second end plates on opposite ends of the unit cells in the first direction; and a side plate on opposite ends of the unit cells in a second direction intersecting the first direction and connected to the end plates, wherein the bus bar comprises a first member extending in the first direction and connected to electrode terminals of the unit cells, and a second member connected to the first member.