Battery Module Sliding Bus Bar Isolation for High-Voltage Safety
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Solution Overview
Problem
Existing battery modules face safety risks due to high voltage applications, particularly in energy storage systems, with conventional solutions like MSD modules being complex and expensive.
Innovation Solution
A battery module design featuring a sliding switching mechanism with a disconnection induction bus bar and a switching slider, allowing manual control of voltage application through a simple sliding motion, ensuring safety by spacing apart overlapping bus bar components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a high voltage is applied to an external terminal of the battery module, then the power output capability is improved, but the safety risk increases due to potential short circuits or earth faults
Solution Approach 1:
The patent implements a dynamic switching mechanism using a sliding switch that can transition between connected and disconnected states. The switching member slides between a first position (connected state) and a second position (disconnected state), allowing the system to dynamically adjust its electrical connectivity based on operational requirements, thereby enabling high power output when needed while maintaining safety when the switch is disconnected
Solution Approach 2:
The patent introduces an intermediate switching mechanism (sliding switch with switching member) that mediates between the high voltage power source and the external terminal. This intermediary component controls the flow of electricity, allowing safe operation by inserting or removing itself from the circuit, thus enabling power output capability while mitigating safety risks through controlled connectivity
2Reliability
If a switching mechanism is added to control voltage application, then the safety is improved, but the device complexity increases
Solution Approach 1:
The patent merges the switching function with the existing bus bar structure by integrating the switching member directly into the electrical connection path. The sliding switch combines the switching mechanism with the bus bar assembly, eliminating the need for separate switching components and reducing overall device complexity while maintaining safety functionality
Solution Approach 2:
The sliding switch mechanism is designed to be manually operated, allowing users to directly control the switching action without requiring complex control systems. The elastic member provides automatic return functionality, and the visual indicator automatically shows the switching state, reducing the need for additional control electronics and simplifying the overall system
3Ease of operation
If the switching member is designed to slide between connected and disconnected positions, then the ease of operation is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent incorporates an elastic member that provides cushioning and tolerance compensation in the switching mechanism. The elastic member absorbs dimensional variations and ensures reliable contact pressure between the switching member and bus bar, reducing the impact of manufacturing precision variations while maintaining smooth operation and reliable switching functionality
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
Enables safe and easy management of voltage application by visually confirming the slider position, preventing live part exposure, and reducing complexity and cost compared to conventional systems.
Implementation Method 1
The disconnection induction bus bar may be elastically supported on the front plate by an elastic member
Implementation Method 2
a disconnection induction bus bar coupled to an inside end of the contact terminal to press and contact the bus bar
Data Source
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AI summary
A battery module is proposed. The battery module includes a plurality of battery sub-modules, and a front cover part configured to cover an outermost stacking surface of the plurality of stacked battery sub-modules. The front cover part includes a front plate including a contact terminal electrically connected to an outside, a bus bar electrically connecting the plurality of battery sub-modules to each other, and a disconnection induction bus bar coupled to an inside end of the contact terminal to press and contact the bus bar, and a switching slider configured to slide between the bus bar and the disconnection induction bus bar.