Battery Module Bus Bar Tin Coating and Connection Protrusions
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Solution Overview
Problem
Existing battery modules face challenges in reliably and efficiently transmitting current and voltage data from rechargeable batteries to a Battery Management System (BMS), often resulting in faulty connections and inaccurate measurements.
Innovation Solution
The battery module incorporates bus bars with connection protrusions and wire sockets that securely connect transmission wires to the BMS, using a support plate with guide members and gas exhaust holes, and coating bus bars with tin to enhance contact resistance and accuracy, ensuring stable and reliable data transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If transmission wires are directly connected to bus bars without connection parts, then the device structure is simpler, but the connection reliability is poor and faulty connections occur
Solution Approach 1:
Connection parts are introduced as intermediary components between transmission wires and bus bars. These connection parts include connection protrusions that extend from the bus bar and wire sockets that grip the transmission wires, providing a reliable intermediate connection structure that eliminates direct contact while ensuring stable electrical connection.
Solution Approach 2:
The connection structure is divided into separate functional components: the bus bar with connection protrusions, the wire sockets with gripping mechanisms, and the transmission wires. This segmentation allows each component to be optimized independently and facilitates easier assembly and maintenance while improving overall connection reliability.
2Measurement precision
If bus bars are not coated, then the manufacturing process is simpler, but the contact resistance is high and measurement accuracy is poor
Solution Approach 1:
The surface properties of the bus bar are modified by coating with tin, which changes the electrical conductivity parameter of the bus bar surface. This coating reduces contact resistance at the connection interface, thereby improving voltage measurement accuracy without fundamentally changing the bus bar structure.
3Reliability
If connection parts are directly attached to bus bars without support plate, then the structure is simpler, but the positional stability is poor and connections are unreliable
Solution Approach 1:
The support plate serves multiple functions simultaneously: it provides mechanical support for the bus bars, positions the connection parts accurately, and guides the transmission wires through integrated guide members. This multi-functional design consolidates several components into one, improving stability without proportionally increasing complexity.
Solution Approach 2:
The support plate with pre-formed guide members and connection part positions is prepared in advance, establishing the correct spatial relationships before final assembly. This preliminary positioning ensures that transmission wires and connection parts align correctly, reducing assembly errors and improving connection reliability.
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 enables accurate and reliable transmission of current and voltage data to the BMS, minimizing the risk of faulty connections and improving the overall management and monitoring of rechargeable batteries.
Implementation Method 1
coating bus bars with tin to enhance contact resistance and accuracy
Data Source
AI summary
A battery module includes a plurality of rechargeable batteries having terminals, bus bars electrically connecting the terminals of the rechargeable batteries, connection parts protruding from the bus bars, and transmission wires electrically connecting the connection parts to a battery management system (BMS), the transmission wires being configured to transmit voltages of the rechargeable batteries to the BMS.