Battery Pack Bus Bar Alignment for Uniform Contact Resistance
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Solution Overview
Problem
Existing battery packs face issues with high electrical resistance, leading to Joule heating and increased risk of accidents such as ignition and explosion due to local Joule heating, particularly in high-power applications.
Innovation Solution
A battery pack design featuring a bus bar with a large conductive area between the bus bar and connection member, aligned by position alignment guides, to form a uniform contact resistance and reduce overall electrical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional bus bar connection is used, then the device complexity is reduced, but the electrical resistance increases leading to Joule heating and safety risks
Solution Approach 1:
Position alignment guides are pre-formed on the bus bar and connection member before assembly, ensuring proper alignment is established in advance during the connection process, which prevents misalignment and ensures optimal contact area without requiring complex post-assembly adjustments
Solution Approach 2:
Position alignment guides act as intermediary elements between the bus bar and connection member, facilitating proper alignment and contact area formation during assembly, thereby ensuring reliable electrical connection while maintaining relatively simple device structure
2Object-affected harmful factors
If a small conductive area is used between bus bar and connection member, then the device complexity is reduced, but local Joule heating increases causing ignition and explosion risks
Solution Approach 1:
The position alignment guides ensure that the contact area between the bus bar and connection member is locally optimized with uniform distribution, creating favorable local conditions for heat dissipation and preventing concentrated Joule heating at specific points while maintaining overall structural simplicity
Solution Approach 2:
The alignment guides are pre-formed on the components themselves, establishing the optimal contact geometry in advance before assembly, which ensures adequate conductive area and uniform contact resistance without requiring complex external fixtures or adjustment mechanisms
3Loss of energy
If a large conductive area is provided between bus bar and connection member, then electrical resistance is reduced and Joule heating is suppressed, but the device complexity increases
Solution Approach 1:
The position alignment guides are integrated directly onto the bus bar and connection member structures, merging the alignment function with the existing components rather than adding separate external alignment devices, thereby achieving large conductive area with minimal increase in overall device complexity
Solution Approach 2:
The position alignment guides serve multiple functions simultaneously: they provide mechanical alignment, ensure proper contact area formation, and contribute to the overall structural integrity of the connection, thereby achieving reduced electrical resistance without proportionally increasing device complexity
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
The design reduces Joule heating and minimizes the risk of accidents by ensuring a uniform conductive area, thereby enhancing safety and efficiency in high-power applications.
Implementation Method 1
the bus bar forms a charge and discharge path for the plurality of battery cells
Implementation Method 2
reduce the overall electrical resistance, suppress the Joule heating, and reduce the risk of accidents such as ignition and explosion caused by local Joule heating
Data Source
AI summary
A battery pack includes a connection member that is aligned with a bus bar to form a charge and discharge path for a group of battery cells forming the battery pack. A large conductive area is formed between the bus bar and the connection member. The configuration provides uniform contact resistance, thereby reducing the overall electrical resistance, suppressing the Joule heating, and reducing the risk of accidents, such as ignition and explosion, due to local Joule heating in a small conductive area.