Battery Module Bus Bar Layout for Stable Fuse Characteristics
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Solution Overview
Problem
Existing battery modules face challenges with increased connection time and cost due to wire bonding for terminal connections, which also results in unstable fuse characteristics due to non-uniform bonding wire lengths and thicknesses.
Innovation Solution
A battery module configuration with conductive members made of metal foil on an insulating plate, allowing for parallel and series connections of unit batteries with exposed terminals, providing a simple structure and increased freedom in arranging batteries, while the conductive members function as fuses by controlling current flow paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire bonding is used to connect terminals to bus bars, then electrical connections can be established, but connection time increases and manufacturing cost increases
Solution Approach 1:
The patent extracts the bonding wire from the system and replaces it with a direct tab-to-bus bar contact structure. The conductive members are positioned to make direct contact with battery tabs, eliminating the intermediate bonding wire component and the complex bonding process, thereby achieving both reliable electrical connection and simplified manufacturing
Solution Approach 2:
The bus bar structure serves multiple functions: it provides electrical connection, acts as a structural support element, and functions as a current collector. This multi-functionality eliminates the need for separate bonding wires and simplifies the overall assembly process while maintaining connection reliability
2Reliability
If wire bonding is used to connect terminals to bus bars, then electrical connections can be established, but manufacturing cost increases
Solution Approach 1:
The patent removes the bonding wire component and the associated bonding equipment requirements from the manufacturing system. The direct contact structure between conductive members and battery tabs eliminates material costs for wires and reduces manufacturing equipment complexity, thereby lowering overall manufacturing cost while maintaining connection reliability
Solution Approach 2:
The patent employs simple, inexpensive conductive members that can be easily manufactured and replaced if needed, rather than using expensive precision wire bonding materials and equipment. This approach prioritizes cost-effective manufacturing while achieving sufficient electrical connection reliability
3Reliability
If bonding wires are used with uniform characteristics, then stable fuse characteristics can be achieved, but it is difficult to ensure uniform lengths and thicknesses in practice
Solution Approach 1:
The patent eliminates the bonding wire from the system entirely, removing the source of variability in length and thickness. The direct contact structure between conductive members and battery tabs provides consistent electrical connection and fuse characteristics without relying on precise wire dimensions, thereby achieving reliable fuse behavior without stringent manufacturing precision requirements
Solution Approach 2:
The patent changes the fundamental parameter of the connection structure from flexible wire with variable dimensions to rigid conductive members with fixed geometry. This parameter change ensures consistent current flow paths and stable fuse characteristics while eliminating the manufacturing precision issues associated with wire bonding
4Reliability
If conventional battery arrangements are used, then cells can be connected in series and parallel, but the degree of freedom in arranging cells is limited
Solution Approach 1:
The bus bar structure is designed to accommodate multiple connection configurations and cell arrangements. The conductive members can be positioned to create series, parallel, or combination connections, and the modular design allows flexibility in arranging cells in different patterns while maintaining reliable electrical connections through the same fundamental structure
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 reduces manufacturing costs, stabilizes fuse characteristics, and enhances the design flexibility of battery modules by simplifying terminal connections and ensuring consistent current handling.
Implementation Method 1
the conductive members are provided with terminal connecting portions connected through the holes to the same-polarity terminals of the respective unit batteries included in the one of the battery blocks
Data Source
AI summary
In a battery module, a plurality of unit batteries in which positive electrode terminals and negative electrode terminals are arranged at one-side ends are arranged in a staggered pattern while the one-side ends are arrayed on the same side, n pieces of battery blocks in which m pieces of the unit batteries adjacent to one another are connected in parallel to one another are connected in series to one another, two or more rows in which the unit batteries are arranged in a direction perpendicular to a series current direction are present on one battery block, the number of the unit batteries in each row is less than or equal to (m−1), an electrically insulating plate is arranged above the one-side ends of the plurality of arrayed unit batteries, the plate is provided with holes from which the positive electrode terminals and the negative electrode terminals of the respective unit batteries are exposed, and is provided with a plurality of conductive members on a surface opposite to a surface facing the unit batteries, and the conductive members extend along the rows in which the unit batteries in the battery blocks are arrayed, two conductive members are arranged with respect to one battery block, and the conductive members are provided with terminal connecting portions connected through the holes to the same-polarity terminals of the respective unit batteries included in one battery block.