Battery Module Bus Bar Elimination via Inclined Cell Housing
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Solution Overview
Problem
The existing battery module designs require multiple bus bars to connect battery cells in series, increasing manufacturing costs and assembly time due to the need for fixing each bus bar to electrode terminals.
Innovation Solution
A battery module design that connects battery cells without using bus bars by employing a configuration where two housing cases house alternating battery cell groups with inclined electrode terminals, allowing direct connection and using a voltage detector with sheet-like base units and conductors to output voltage information, eliminating the need for bus bars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bus bars are used to connect battery cells in series, then reliable electrical connection is achieved, but manufacturing cost increases and assembly time is extended
Solution Approach 1:
The patent extracts and eliminates the bus bar component from the battery module structure. Instead of using separate bus bars to connect battery cells, the invention integrates the connection function directly into the housing case through conductive portions that make contact with electrode terminals, thereby removing the need for additional bus bars and reducing manufacturing cost while maintaining connection reliability
Solution Approach 2:
The patent merges the housing case structure with the electrical connection function. The housing case is designed to include conductive portions that directly contact the electrode terminals of battery cells, combining the structural support function and electrical connection function into a single integrated component, thereby eliminating the need for separate bus bars
2Reliability
If bus bars are used to connect battery cells, then electrical connection is established, but the number of parts increases and assembly complexity increases
Solution Approach 1:
The housing case is designed to include conductive portions that directly contact the electrode terminals, merging the structural support function and electrical connection function into a single integrated component. This reduces the total number of parts and simplifies the assembly process by eliminating the need to separately install bus bars
Solution Approach 2:
The housing case serves multiple functions: it provides structural support for the battery cells and simultaneously establishes electrical connections through its conductive portions. This multi-functionality reduces the number of components needed and simplifies the overall assembly process
3Reliability
If bus bars are fixed to electrode terminals, then electrical connection is secured, but manufacturing time increases and workability decreases
Solution Approach 1:
The housing case is designed so that its conductive portions are inherently positioned to contact the electrode terminals when the battery cells are installed. This integrated design eliminates the need for separate fixing operations required for bus bars, thereby reducing assembly time and improving productivity while maintaining connection stability
Data Source
AI summary
A battery module includes a plurality of battery cells each having two electrode terminals, i.e., positive and negative electrode terminals; a first housing case that houses a first battery cell group; a second housing case that houses a second battery cell group; and a fixing tool that fixes the first and the second housing cases by making the electrode terminals in the first battery cell group face the electrode terminals in the second battery cell group. The second battery group is housed in the second housing case while being inclined relative to the first battery cell group, connected to the negative electrode terminal of each battery cell in the first battery cell group facing the positive electrode terminal of the battery cell, and connected to the positive electrode terminal of each battery cell in the first battery cell group facing the negative electrode terminal of the battery cell.