Battery Module Dual Bus Bar Joining Forms
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Solution Overview
Problem
Conventional battery modules lack the ability to readily adjust the number of battery cells, making it difficult to match varying usage purposes and performance requirements, and the process of connecting or disconnecting cells is cumbersome, especially during maintenance.
Innovation Solution
The battery module employs a dual bus bar system with different joining forms, where the first bus bar uses fixation with a bolt for easy attachment and detachment, and the second bus bar uses welding for secure connections, allowing for flexible adjustment of the number of battery cells and improved maintainability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single joining form is used for all bus bars, then the structure is simple and easy to manufacture, but the ability to adjust the number of battery cells is limited and maintenance becomes cumbersome
Solution Approach 1:
The bus bar system is segmented into multiple types (first bus bars with first joining form, second bus bars with second joining form) that perform different functions. This segmentation allows the system to achieve both simplicity in individual components and versatility in overall configuration, resolving the contradiction between ease of manufacture and adaptability.
Solution Approach 2:
Different bus bars are designed with different joining forms to serve multiple functions: some bus bars enable easy assembly/disassembly for maintenance, while others provide strong permanent connections for structural stability. This multi-functionality approach allows a single bus bar system to achieve both simplicity and adaptability simultaneously.
2Reliability
If a permanent joining form like welding is used for all bus bars, then the connection reliability is high, but the ease of maintenance and cell replacement is reduced
Solution Approach 1:
Different joining forms are applied to different locations in the bus bar system based on local requirements. Areas requiring high reliability and stability use permanent joining forms like welding, while areas requiring maintenance access use detachable joining forms. This local differentiation resolves the contradiction between connection reliability and ease of repair.
Solution Approach 2:
The bus bar system is divided into segments with different joining characteristics. Some segments use welding for reliable permanent connections, while other segments use detachable connections for easy maintenance. This segmentation allows the system to achieve both high reliability and ease of repair simultaneously.
3Ease of repair
If detachable joining forms are used for all bus bars, then the ease of maintenance and adjustment is improved, but the connection reliability and firmness are reduced
Solution Approach 1:
detachable joining forms are applied locally only where maintenance and adjustment are required, while permanent joining forms are used in areas where connection reliability is critical. This local quality differentiation resolves the contradiction between ease of repair and connection reliability.
4Adaptability or versatility
If the bus bar system is designed for easy disassembly, then the adjustability of battery cell number is improved, but the structural stability and connection strength are reduced
Solution Approach 1:
The bus bar system is segmented into different connection types: detachable connections for areas requiring adjustability and permanent welded connections for areas requiring strength. This segmentation allows the system to achieve both adaptability and strength simultaneously without compromise.
Solution Approach 2:
The bus bar system incorporates multiple joining forms to serve different functions: detachable connections provide adjustability while welded connections provide structural strength. This multi-functionality resolves the contradiction between adaptability and strength.
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 easy adjustment of the number of battery cells, reduces energy loss due to varying electric resistance, and simplifies maintenance by allowing for straightforward connection and disconnection of cells, enhancing the module's reliability and maintainability.
Implementation Method 1
The first joining form is fixation with a bolt, pin, clip or band
Implementation Method 2
the second joining form is welding
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A battery module (100) includes: a plurality of battery cells (11) stacked in a predetermined direction; a restraint member (41) that applies, to the plurality of battery cells (11), restraint force along the predetermined direction; and a plurality of bus bars (50) that electrically connects the plurality of battery cells (11) together, the plurality of bus bars (50) including a first bus bar (51) and a second bus bar (52). The first bus bar (51) has a first joining portion (66) that joins separated members to each other by a first joining form, and connects, via the first joining portion (66), between battery cells (11) adjacent to each other in the predetermined direction. The second bus bar (52) has a second joining portion (69) that joins separated members to each other by a second joining form different from the first joining form, and connects, via the second joining portion (69), between battery cells (11) adjacent to each other in the predetermined direction.