Bus Bar Assembly With Elastic Compression For Battery Module
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Solution Overview
Problem
Conventional bus bar assemblies require bending of electrode leads for connection, which is labor-intensive and results in poor adhesion due to the elastic restoration force of metal electrode leads, especially when connecting multiple leads in parallel.
Innovation Solution
A bus bar assembly featuring an insertion-type bus bar with side-adhering bus bars and a supporting leaf spring that allows electrode leads to be inserted without bending, providing mechanical compression for reliable welding and electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrode leads are bent to contact the bus bar for welding, then electrical connection is achieved, but manual labor increases and adhesion reliability deteriorates due to elastic restoration force
Solution Approach 1:
Instead of bending the electrode lead to contact the bus bar, the invention inverts the approach by having the bus bar assembly actively press against the straight electrode lead. The compression member applies force to push the bus bar contact portion against the electrode lead, eliminating the need for manual bending operations while ensuring reliable adhesion through continuous compressive force.
Solution Approach 2:
The bus bar assembly is designed to automatically maintain electrical connection through its own structural features. The compression member continuously applies force to press the bus bar contact portion against the electrode lead, creating a self-sustaining connection that does not require external manual intervention or complex fixing mechanisms.
2Power
If multiple electrode leads are connected in parallel by overlapping on the bus bar, then current capacity increases, but welding difficulty increases and welding quality deteriorates
Solution Approach 1:
The bus bar assembly is divided into multiple contact portions, each designed to independently contact and press against individual electrode leads. This segmentation allows multiple leads to be connected in parallel without interfering with each other, maintaining good welding accessibility for each lead while achieving the required current capacity.
Solution Approach 2:
Instead of requiring multiple electrode leads to be manually positioned and overlapped on the bus bar, the invention inverts the approach by having the bus bar assembly actively press against the leads. The compression member applies force to ensure each contact portion maintains reliable electrical connection, simplifying the manufacturing process while supporting parallel connections for high current capacity.
3Reliability
If electrode leads are bent to fit the bus bar, then connection is achieved, but the elastic restoration force causes poor adhesion
Solution Approach 1:
Instead of relying on bent electrode leads to maintain contact, the invention inverts the approach by having the bus bar assembly actively press against the straight electrode leads. The compression member continuously applies compressive force to ensure the bus bar contact portion maintains reliable electrical connection, eliminating the adverse effect of elastic restoration force that would otherwise cause poor adhesion.
Solution Approach 2:
The compression member is designed to apply compressive force in advance and continuously maintain it during operation. This preliminary action ensures that the bus bar contact portion is already pressed against the electrode lead before welding and maintains this pressure throughout the welding process and subsequent operation, ensuring strong adhesion and reliable electrical connection without the interference of elastic restoration force.
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
Eliminates the need for manual bending, enhances the reliability of electrical and mechanical bonding, and improves automation in battery module production by ensuring secure and efficient connection of multiple electrode leads in parallel.
Implementation Method 1
a supporting and holding member configured to support the insertion-type bus bar at a location protruding further to the side-adhering bus bars, the supporting and holding member being elastically deformed by the insertion-type bus bar
Data Source
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AI summary
Disclosed is a bus bar assembly for electrically connecting a plurality of battery cells having electrode leads. The bus bar assembly includes an insertion-type bus bar provided in the form of a rod-shaped conductor; side-adhering bus bars positioned with the insertion-type bus bar being interposed therebetween to form fitting spaces respectively beside both sides of the insertion-type bus bar so that at least one electrode lead is inserted in the fitting spaces; and a supporting and holding member configured to support the insertion-type bus bar at a location protruding further to the side-adhering bus bars, the supporting and holding member being elastically deformed by the insertion-type bus bar to be positioned on the same plane as the side-adhering bus bars when the insertion-type bus bars are pressed.