Buffered Bus Bar Structure for Battery Terminal Stress Relief
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Solution Overview
Problem
Existing bus bars struggle to mitigate stress applied to the joint parts with the terminal parts of electric storage devices due to fluctuations in terminal distances caused by expansion and contraction of the devices.
Innovation Solution
A bus bar configuration that includes a first joint area, a second joint area, and a cross-linked area, with buffering parts on at least one of the joint areas to absorb stress caused by fluctuations in the interval between the joint areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bus bar is joined to terminal parts of electric storage devices by laser welding or resistance welding, then electrical connection is achieved, but stress from terminal distance fluctuation is applied to the joint parts
Solution Approach 1:
A buffering part is introduced as an intermediary element between the bus bar main body and the joint parts. This buffering part absorbs the stress caused by terminal distance fluctuation, preventing direct transmission of stress to the welded joint parts, thereby protecting the reliability of the electrical connection.
Solution Approach 2:
The buffering part is designed in advance to cushion and absorb the stress that will be generated by thermal expansion and contraction of the electric storage devices. By providing this protective structure beforehand, the joint parts are pre-protected from stress damage during operation.
2Stress or pressure
If a bent part is provided between connecting parts to follow terminal distance fluctuation, then stress on bus bar main body is mitigated, but stress on joint parts cannot be mitigated
Solution Approach 1:
The bus bar is segmented into distinct functional zones: the bus bar main body, the buffering part, and the joint parts. This segmentation allows the buffering part to specifically handle stress absorption while the joint parts maintain their welding connection functionality, resolving the contradiction between stress mitigation and joint reliability.
Solution Approach 2:
The buffering part serves as a mediator between the rigid bus bar main body and the joint parts. It decouples the stress absorption function from the electrical connection function, allowing the joint parts to remain reliable while still protecting against stress from terminal distance fluctuations.
3Reliability
If buffering parts are added to absorb stress, then joint part reliability is improved, but device complexity increases
Solution Approach 1:
The buffering part is merged with the bus bar as an integrated structure rather than a separate component. This merging approach allows the buffering function to be added without requiring additional assembly steps or separate parts, thereby minimizing the increase in device complexity while still improving joint part reliability.
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 buffering parts effectively absorb stress, reducing its application to the joint parts between the bus bar and the terminal parts, thereby enhancing the durability and reliability of the bus bar connections.
Implementation Method 1
a buffering part is provided on at least one of the first joint area and the second joint area, which is configured to absorb a stress caused by a fluctuation of an interval between the first joint area and the second joint area
Data Source
AI summary
The herein disclosed bus bar 1 includes a first joint area that is joined to a terminal part of a first electric storage device, includes a second joint area that is joined to a terminal part of the second electric storage device, and includes a cross-linked area connecting the first joint area and the second joint area. Then, on at least one of the first joint area and the second joint area, a buffering part is provided that is configured to absorb a stress caused by a fluctuation of an interval between the first joint area and the second joint area. The bus bar having the above described configuration can mitigate the stress applied onto the joint part of the terminal part of the bus bar.