Bridge Bus Bar Layout for Safer High-Voltage Battery Modules
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Solution Overview
Problem
High-voltage battery modules pose increased risk of electric shock due to higher current flow, necessitating safety measures to minimize human injury during manufacture and use.
Innovation Solution
The battery module design includes a bridge bus bar that electrically connects separated bus bars at the second vertical plate, with a bridge coupling unit, allowing safe electrical connection only after assembly, and is integrated with a mono frame and side frames for protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-voltage battery module uses conventional bus bar structure with all electrical connections assembled together, then electrical connection reliability is improved, but risk of electric shock to human body during manufacture and transportation increases
Solution Approach 1:
The bus bar structure is divided into first bus bars and second bus bars that are electrically separated from each other during assembly and transportation. The electrode leads are connected to respective bus bars in a segmented manner, with electrical connection between first and second bus bars established only after assembly through bridge bus bars, thereby reducing voltage exposure risk during handling while maintaining connection reliability.
Solution Approach 2:
The electrode leads are preliminarily connected to the first and second bus bars separately before final assembly. The bridge bus bars are prepared in advance but not connected to the main bus bars until the assembly stage, ensuring that full voltage potential is not present during manufacturing and transportation operations.
2Object-affected harmful factors
If bridge bus bar structure is used to separate electrical connections during assembly, then safety against electric shock is improved, but device complexity increases
Solution Approach 1:
The bridge bus bars are designed to electrically connect the first and second bus bars after assembly, merging the segmented electrical connections into a complete circuit. This merging occurs only after the safety-critical assembly stage, maintaining simplicity during manufacturing while achieving full functionality in the final product.
Solution Approach 2:
The bridge bus bars act as intermediary elements that connect the first and second bus bars. These intermediaries are introduced only when necessary (after assembly) to complete the electrical circuit, allowing the system to maintain safety during assembly while achieving full electrical functionality afterward.
3Reliability
If all bus bars are electrically connected during assembly process, then electrical conductivity is improved, but manufacturing safety decreases
Solution Approach 1:
The electrical connectivity of the bus bar system is made dynamic rather than static. During assembly and transportation, the system maintains electrical separation between first and second bus bars. After assembly, the bridge bus bars are connected to establish full electrical conductivity. This dynamic approach allows the system to adapt its electrical state to the operational phase, ensuring safety during manufacturing while achieving full conductivity in operation.
Data Source
AI summary
Disclosed herein is a high-voltage battery module including a bridge bus bar configured to be exposed to the outside in order to reduce a danger of accident due to electric shock when handing the high-voltage battery module, wherein a cell assembly is temporarily electrically open-circuited and the bridge bus bar is connected only when the battery module is used. It is possible to remove dangerous factors that may injure the human body during manufacture and transportation of the high-voltage battery module and to use the high-voltage battery module in the state in which restrictions are minimized.