Bus Bar Module Layout for Bypassing Battery Cell Projections
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Solution Overview
Problem
Conventional bus bar modules face challenges in connecting electrode terminals of adjacent battery cells while avoiding projections such as partition walls or exhaust ducts, leading to interference with electric wires and inefficient electrical connections.
Innovation Solution
A bus bar module design featuring a first bus bar extended in the arrangement direction and a second U-shaped bus bar that bypasses projections, combined with an insulating housing case that guides electric wires around the projections, ensuring seamless electrical connections and wire routing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a straight bus bar is used to connect adjacent electrode terminals, then the electrical connection is simple and direct, but the bus bar cannot avoid projections such as partition walls or exhaust ducts in the battery module
Solution Approach 1:
The bus bar is divided into multiple segments or sections, allowing it to navigate around projections while maintaining electrical connection. The bus bar includes a first section connected to a first electrode terminal, a second section connected to a second electrode terminal, and intermediate sections that route around obstacles, enabling the bus bar to adapt to the battery module's internal geometry without compromising manufacturing simplicity
Solution Approach 2:
The bus bar transitions from a straight linear path to a three-dimensional routed path that goes around projections. By utilizing vertical clearance and lateral space within the battery module, the bus bar can bypass partition walls and exhaust ducts while still connecting adjacent electrode terminals effectively
2Reliability
If the bus bar is routed to bypass projections, then the bus bar can connect electrode terminals without interference, but the electrical connection path becomes longer and more complex
Solution Approach 1:
The bus bar design incorporates intermediate connection sections that act as mediators between the straight connection path and the bypass path. These intermediate sections include connection holes or attachment points that allow the bus bar to transition smoothly around projections while maintaining continuous electrical conductivity and structural integrity
Solution Approach 2:
The bus bar's geometric parameters are modified to accommodate projections, including changes in length, curvature, and cross-sectional orientation. The bus bar may include bent sections, angled portions, or three-dimensional routing that changes its spatial parameters while maintaining optimal electrical connection properties and avoiding interference with battery module components
3Ease of operation
If electric wires are routed near projections, then wire routing is simplified, but the wires may interfere with projections causing electrical or physical issues
Solution Approach 1:
The electric wire routing is separated from the projection areas by dedicating specific routing paths that exclude projections. The wire routing is extracted from general space and assigned to specific channels or conduits that naturally avoid projections, eliminating potential interference while maintaining routing simplicity through planned path designation
Data Source
AI summary
A second bus bar of a bus bar module includes a first electrical connection part connected to one electrode terminal, a second electrical connection part connected to another electrode terminal, and a U-shaped bypass part that connects the first and the second electrical connection parts and bypasses a projection on a battery module. A housing case includes a first bus bar housing part that houses a first bus bar, a second bus bar housing part that houses the first electrical connection part, a third bus bar housing part that houses the second electrical connection part, and an electric wire housing part that guides an electric wire along a bottom wall that is disposed to be opposed to the battery module. The electric wire housing part is disposed adjacent to the first bus bar housing part, the second bus bar housing part, and the third bus bar housing part.