Battery Module Bus Bar Cover Insulation Design
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Solution Overview
Problem
Battery modules face insulation challenges with bus bars, leading to potential short circuits and safety hazards due to high-voltage charge/discharge currents, and existing insulation structures are complex and costly.
Innovation Solution
A battery module design featuring first and second bus bars adjacent to each other, covered by a bus bar cover with hollow portions and insulating walls, which collectively insulates the bus bars from each other and the external environment, simplifying the insulation structure and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate insulation structures are provided for each bus bar, then insulation reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple insulation functions into a single integrated bus bar cover that simultaneously insulates adjacent bus bars from each other and insulates them from the external environment. This merging of insulation structures reduces the number of separate components while maintaining comprehensive insulation coverage, directly resolving the contradiction between insulation reliability and structural complexity.
Solution Approach 2:
The bus bar cover is designed as a multi-functional component that performs multiple insulation tasks: it provides electrical isolation between adjacent bus bars, protects against external environmental factors, and maintains structural integrity. This universal design approach allows a single component to fulfill multiple insulation requirements, reducing overall device complexity while ensuring reliable insulation.
2Reliability
If multiple separate insulation components are used for bus bars, then insulation coverage is improved, but manufacturing cost increases
Solution Approach 1:
The patent integrates multiple insulation functions into a single bus bar cover component, eliminating the need for multiple separate insulation parts. This consolidation reduces manufacturing complexity, lowers material costs, and simplifies assembly processes while maintaining comprehensive insulation coverage across all adjacent bus bars.
Solution Approach 2:
The single bus bar cover component is designed to universally address multiple insulation needs simultaneously, providing cost-effective protection against short circuits and environmental interference. This multi-functional design reduces the total component count and associated manufacturing expenses while ensuring complete insulation coverage.
3Ease of operation
If bus bars are exposed for electrical connection, then ease of operation is improved, but risk of short circuit increases
Solution Approach 1:
The bus bar cover incorporates segmented hollow portions and coupling hole exposures that provide targeted access points for electrical connections while maintaining insulation coverage in other areas. This segmentation allows operational accessibility where needed while preserving protective insulation where short circuit risks exist, resolving the contradiction between ease of operation and safety.
Solution Approach 2:
The bus bar cover acts as an intermediary structure that selectively exposes coupling holes for necessary electrical connections while insulating the majority of the bus bar surfaces. This mediator approach enables controlled accessibility for operations while maintaining comprehensive protection against harmful short circuit conditions.
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 provides effective insulation against short circuits and external interference, preventing malfunction and safety accidents while reducing the complexity and cost of the insulation structure.
Implementation Method 1
a bus bar cover covering and insulating the first and second bus bars from the outside thereof and insulating the first and second bus bars from each other
Data Source
AI summary
A battery module is provided. The battery module includes: first and second bus bars arranged adjacent to each other to electrically connect battery packs adjacent to each other; and a bus bar cover covering and insulating the first and second bus bars from the outside thereof and insulating the first and second bus bars from each other, wherein the bus bar cover includes a hollow portion exposing a coupling hole of the first and second bus bars. Accordingly, sufficient insulation may be secured for the bus bars electrically connecting different battery packs, malfunction and safety accidents caused by the short circuit of the bus bars through which high-voltage charge/discharge currents flow may be prevented, and the insulation structure of the bus bars may be simplified by accommodating different adjacent bus bars together.