Blind Rivet Sensor Wire Attachment for Battery Bus Bars

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Solution Overview

Problem

Existing methods for attaching voltage sense wires to bus bars in battery modules are inefficient due to space constraints, require double-sided access, and are prone to loosening or failure over time, especially in tightly-packed modules.

Innovation Solution

The use of a blind rivet to securely attach sensor wires, including voltage sense wires, to bus bars by passing through a rivet hole, providing a compression force and forming an electrically conductive bond without the need for double-sided access and adhesive curing, with options for ring terminals or loop terminals.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a bolt is used to attach the sensor wire to the bus bar, then the electrical connection can be established, but significant z-dimensional space is required and access to both sides of the bus bar is needed

Engineering Contradiction:

Improveelectrical connectionVSAvoidz-dimensional space

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent inverts the traditional bolt attachment approach by using a blind rivet that is installed from only one side of the bus bar. Instead of requiring access to both sides for bolt installation, the rivet is set from the front side only, with the deformation occurring inside the bus bar to create the electrical connection. This inversion of the installation approach eliminates the need for double-sided access while maintaining reliable electrical connectivity.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent transitions from a three-dimensional bolt installation requiring access in multiple directions (front and back sides) to a two-dimensional solution where the attachment is achieved from a single plane. The blind rivet creates a planar installation interface on the front side of the bus bar, while the electrical connection is established through the thickness dimension internally, reducing the z-dimensional space requirement.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If a bolt is used to attach the sensor wire to the bus bar, then the electrical connection can be established, but access to both sides of the bus bar is required

Engineering Contradiction:

Improveelectrical connectionVSAvoidaccess requirement

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of manufacture

If adhesive is used to attach the sensor wire to the bus bar, then the attachment can be made, but time is required for the adhesive to cure

Engineering Contradiction:

Improveattachment capabilityVSAvoidcuring time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The patent replaces the adhesive bonding process (which requires chemical curing time) with a mechanical blind rivet system. The rivet is installed and sets immediately through mechanical deformation, providing instant structural and electrical connection without any waiting period for chemical curing. This substitution eliminates the time loss associated with adhesive curing while maintaining secure attachment capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution enables fast, robust, and space-efficient attachment of sensor wires, enhancing electrical conductivity and reliability, while eliminating the need for adhesive curing and double-sided access, thus improving the stability and efficiency of battery module monitoring systems.

Implementation Method 1

The blind rivet can provide a significant compression force between the terminal end of the sensor wire and the bus bar, thereby increasing electrical conductivity between the two

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

The blind rivet can provide a significant compression force between the terminal end of the sensor wire and the bus bar, thereby increasing electrical conductivity between the two

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS11660657B2Bus bar to sensor wire attachment using a blind rivet

Publication Date: 2023.05.30 RIVIAN HOLDINGS LLC

AI summary

Systems and methods that provide an improved mechanism for attaching a sensor wire to a bus bar in a battery module are disclosed. A battery module according to the present disclosure may include a bus bar comprising a rivet hole and a plurality of battery cells electrically coupled to the bus bar. The battery module may also include a sensor wire comprising a terminal end, as well as a blind rivet passing through the rivet hole of the bus bar and coupling the bus bar to the terminal end of the sensor wire. Attaching the sensor wire to the bus bar with a blind rivet may provide one or more of the following mechanical advantages: fast assembly, robustness for low power applications, elimination of the need to wait for an adhesive to cure, and elimination of the need for double-sided access of the bus bar.