Integrated Bus Bar Assembly for Battery Module Short Circuit Prevention
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Solution Overview
Problem
Existing battery modules face challenges in compact and stable assembly with reduced complexity and risk of short circuits and misassembly due to the need for multiple mechanical and electrical connection members, which increases system size and complexity.
Innovation Solution
A bus bar assembly with integrally formed bus bars on an insulative cover plate allows for parallel connection of battery cells without additional mechanical fastening members, ensuring easy assembly and preventing short circuits, using a compact and stable structure with exposed electrode terminals and a module case.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple bus bars and mechanical fastening members are used to electrically connect battery cells in series or parallel, then the battery module can achieve required output and capacity, but the assembly process becomes very complicated and the number of parts increases
Solution Approach 1:
The patent combines multiple bus bars into a single integrated bus bar structure that can electrically connect multiple battery cells simultaneously. This single bus bar structure replaces what would traditionally require multiple separate bus bars and mechanical fastening members, thereby reducing part count and simplifying the assembly process while maintaining the required electrical connectivity for achieving desired power output and capacity.
2Reliability
If power cables or bus bars are used to directly achieve electrical connection of battery cells, then electrical connectivity is achieved, but short circuit may occur due to tools during assembly and misassembly can happen
Solution Approach 1:
The patent introduces an insulating structure as an intermediary element between the bus bar and battery cell terminals. This insulating structure includes positioning protrusions that guide the bus bar into correct alignment with the battery cell terminals, preventing misassembly. The insulating material also prevents short circuits during assembly by isolating conductive elements until proper connection is established, thereby eliminating short circuit risks from tools and preventing assembly errors.
3Ease of operation
If additional connectors or plug-in connectors are used to easily achieve electrical connection, then assembly becomes easier, but the number of unnecessary parts increases
Solution Approach 1:
The patent merges the electrical connection function and mechanical positioning function into a single integrated bus bar structure with built-in positioning protrusions. This eliminates the need for separate connectors or plug-in components, as the bus bar itself provides both the electrical connection pathway and the alignment guidance through its integrated positioning features, thereby maintaining ease of assembly while reducing the total number of parts.
4Reliability
If space is allocated for coupling, welding, or soldering mechanical fastening and electrical connection members, then secure connections are achieved, but the total size of battery system increases
Solution Approach 1:
The patent combines electrical connection and mechanical positioning functions into a single integrated bus bar structure, eliminating the need for separate mechanical fastening members. This integration reduces the space required for connection components and their associated assembly operations (coupling, welding, soldering), thereby reducing the overall battery system volume while maintaining reliable electrical connections through the unified structure.
Data Source
AI summary
Disclosed herein is a battery module including a unit module assembly including unit modules, each of which includes a plurality of battery cells or a plurality of cell assemblies, each of which includes two or more battery cells, as unit cells, the unit modules being arranged while being adjacent to each other, each of the unit modules having electrode terminals arranged at one side thereof, a battery disconnect unit (BDU) arranged at one side of the unit module assembly, the battery disconnect unit having terminal connection parts arranged at the same side as the electrode terminals, a module case in which the unit modules of the unit module assembly are mounted, the electrode terminals of the unit modules being exposed through the module case, and a bus bar assembly including a cover plate mounted on the electrode terminals of the unit modules at the module case, the cover plate being formed of an insulative material, and two more bus bars mounted to the cover plate.