Insulated Bus Bar Reinforcement for Vibration-Resistant Battery Modules
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Solution Overview
Problem
The durability of battery modules is compromised due to the weak mechanical stiffness of bus bars, which can lead to damage and disconnection of electrical connections under conditions of external shock or frequent vibration, especially when used in vehicles.
Innovation Solution
A battery module design that includes a bus bar with a plate-shaped body and connection portions for electrode terminals, an insulation sheet with exposure holes for adhesive application, and an adhesive with electric insulation to enhance mechanical rigidity and prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the bus bar is made with standard mechanical structure, then the electrical connection is achieved, but the mechanical stiffness is insufficient leading to damage under external shock or vibration
Solution Approach 1:
The bus bar is constructed as a composite structure consisting of a metal plate body with reinforced ribs integrated into it. The metal plate provides electrical conductivity and base strength, while the ribs (which may be made of metal or plastic material) add mechanical stiffness and structural reinforcement without significantly increasing weight or complexity. This composite approach resolves the contradiction by achieving enhanced mechanical strength while maintaining reasonable structural complexity.
2Reliability
If the bus bar structure is simplified, then the manufacturing is easier, but the durability under vibration and shock is reduced
Solution Approach 1:
The bus bar structure is segmented into distinct functional elements: a flat plate body for electrical connection and integrated ribs for structural reinforcement. This segmentation allows each component to be optimized independently - the plate for electrical conductivity and the ribs for mechanical strength - while being manufactured as an integrated piece through stamping or molding processes, thus maintaining ease of manufacture while improving durability.
Solution Approach 2:
The functional elements of electrical conduction (plate body) and mechanical support (ribs) are merged into a single integrated bus bar component. This merging eliminates the need for separate assembly steps for attaching reinforcement elements, simplifying manufacturing while ensuring that the electrical and mechanical functions work together harmoniously to improve overall reliability under vibration and shock conditions.
3Reliability
If the bus bar is reinforced to prevent damage, then the durability is improved, but the weight increases
Solution Approach 1:
Instead of uniformly thickening the entire bus bar, ribs are strategically positioned only in areas requiring additional mechanical strength, such as near connection points and along the length where bending moments are highest. This local reinforcement approach provides the necessary durability improvement while minimizing the addition of weight, as the reinforcement is applied only where structurally necessary rather than throughout the entire component.
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 solution significantly improves the durability of the battery module by preventing damage to the bus bar and maintaining electrical connections even under conditions of external shock or frequent vibration, thereby enhancing the module's overall reliability.
Implementation Method 1
an adhesive having electric insulation and applied to the at least a part of the bus bar exposed to the outside through the exposure hole of the insulation sheet
Data Source
AI summary
Disclosed is a battery module and a battery pack with improved durability. The battery module includes a plurality of cylindrical battery cells each respectively having electrode terminals; a module case having an accommodation portion in which the plurality of cylindrical battery cells are accommodated; a bus bar including a plate-shaped and electrically conductive body portion, and a connection portion configured to contact the electrode terminals to electrically connect the plurality of cylindrical battery cells to each other; an electrically insulating insulation sheet covering an outer side of the bus bar, the insulation sheet having an exposure hole through which at least a part of the bus bar is exposed to an outside; and an electrically insulating adhesive on the at least a part of the bus bar exposed to the outside through the exposure hole of the insulation sheet.