Bus Bar Module With Elastic Projection For Battery Cell Alignment
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Solution Overview
Problem
The existing bus bar modules face instability in fastening due to varying height positions of single cells in a battery assembly, leading to potential displacement and unstable electrical connections between adjacent electrodes.
Innovation Solution
A bus bar module design where the bus bar's projection is elastically deformable, supported by a narrower support portion that allows for line contact with the back surface of the projection, enabling absorption of displacement and maintaining a stable electrical connection by preventing side surface contact, which facilitates easy alignment and secure fastening even with multiple electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the bus bar is rigidly supported by a wide support portion, then structural stability is improved, but the ability to absorb displacement between electrodes deteriorates
Solution Approach 1:
The bus bar projection is designed with flexible, thin-walled structures that can elastically deform to absorb displacement between electrodes. The projection includes side plate portions with relatively thin walls that can bend and flex while maintaining structural integrity, allowing the bus bar to adapt to height variations in adjacent single cells without requiring a wide, rigid support portion.
Solution Approach 2:
The support portion width is specifically designed to be smaller than the interval between inner side surfaces of the side plate portions, creating a geometric parameter relationship that enables elastic deformation. This parameter configuration allows the projection to flex and absorb displacement while the support portion provides minimal structural guidance, transforming the rigid-support model into a flexible-adaptation model.
2Adaptability or versatility
If the support portion width is reduced to allow elastic deformation, then adaptability to electrode displacement is improved, but structural support strength deteriorates
Solution Approach 1:
The bus bar is segmented into distinct functional regions: the projection portion that provides electrical connection and absorbs displacement through elastic deformation, and the support portion that provides minimal structural guidance. This segmentation allows each part to be optimized independently - the projection for flexibility and the support for stability - resolving the contradiction between deformability and support strength.
Solution Approach 2:
The projection is designed with thin-walled side plate portions that can elastically deform while maintaining sufficient structural strength. The thin walls provide the necessary flexibility to absorb displacement between electrodes of varying heights, while the overall geometry and material properties ensure the projection maintains adequate strength for electrical connection and mechanical stability.
3Stability of the object's composition
If the support portion contacts the inner surfaces of side plate portions, then structural stability is improved, but the ease of elastic deformation deteriorates
Solution Approach 1:
The support portion width is deliberately made asymmetric relative to the side plate portions - specifically smaller than the interval between their inner surfaces. This asymmetric design creates intentional clearance that prevents contact between the support portion and the inner surfaces of the side plate portions, allowing the projection to deform freely in the vertical direction while maintaining lateral stability through the support portion's position.
Solution Approach 2:
The support portion acts as an intermediary element that provides minimal structural guidance without constraining the elastic deformation of the projection. By positioning the support portion to contact only the back surface of the projection and not the inner surfaces of the side plate portions, it serves as a mediator that enables rather than hinders the desired flexible behavior.
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
This design ensures a stable and reliable electrical connection by absorbing displacement through elastic deformation, maintaining a predetermined fixing force and enhancing connection reliability across varying cell heights.
Implementation Method 1
the projection of the bus bar supported on the support portion is easily elastically deformed. Therefore, even if displacement in an assembling direction of the bus bar occurs between the electrodes of the adjacent single cells, it is possible to easily absorb the displacement by the elastic deformation of the projection
Data Source
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AI summary
A bus bar includes a plurality of fastening holes in which a plurality of electrodes of a single cell is fastened with a nut, and a plurality of projections formed between the fastening holes and projecting in a direction away from the single cell. A case includes a bus bar hosing portion in which the bus bar is housed, and a support portion disposed in the projection of the bus bar housed in the bus bar housing portion and abutting against a back surface of the projection to support the bus bar. The support portion has a width smaller than an interval between inner side surfaces of side plate portions of the projection.