Bus Bar Module With Flexible Arch Joining Member
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Solution Overview
Problem
Conventional bus bar modules for assembled batteries, particularly those in hybrid or electric vehicles, face issues where the arch-shaped joining member can deform or damage electrodes under load from above, and increasing installation space to avoid interference with smoke-emitting ducts is not feasible.
Innovation Solution
A bus bar module design featuring a holding member with arch-shaped joining members that include a rigid part for maintaining shape and a flexible part to absorb loads, preventing load transmission to the electrodes without requiring additional installation space, achieved by forming the flexible part in a flat plate shape and positioning it at the lower end of the joining member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an arch-shaped joining member is used to avoid interference with the smoke-emitting duct, then the smoke-emitting duct can be positioned regularly, but the electrode may be deformed or damaged under load from above
Solution Approach 1:
The joining member is divided into a rigid part and a flexible part. The rigid part maintains the arch shape to avoid interference with the smoke-emitting duct, while the flexible part absorbs loads to prevent electrode damage. This segmentation allows each part to fulfill its specific function independently.
Solution Approach 2:
Different parts of the joining member have different mechanical properties. The rigid part provides structural support and maintains the arch shape, while the flexible part provides load absorption. This local differentiation of material properties resolves the contradiction between maintaining shape and absorbing load.
2Ease of operation
If the arch-shaped joining member is designed to stride over the smoke-emitting duct, then the smoke-emitting duct positioning is regular, but the installation space increases
Solution Approach 1:
The flexible part of the joining member can dynamically adjust its shape under load, bending vertically to reduce the required clearance between the joining member and the upper panel. This dynamic behavior allows the maintaining of a regular duct positioning without excessive installation space.
3Shape
If the joining member is made rigid to maintain arch shape, then the smoke-emitting duct can be avoided, but the load from above is transmitted to the electrode
Solution Approach 1:
The joining member is segmented into rigid and flexible portions. The rigid part maintains the arch shape for duct avoidance, while the flexible part provides load absorption to protect the electrode. This segmentation resolves the contradiction between shape maintenance and electrode protection.
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 design effectively reduces the risk of electrode deformation or damage from above loads without increasing installation space, ensuring the bus bar module can maintain electrical connectivity and structural integrity in compact battery assemblies.
Implementation Method 1
a flexible part adapted to vertically bend by a load from above
Data Source
AI summary
A bus bar module includes a holding member for holding the plural bus bars with a mutual distance between the bus bars maintained. The holding member includes a first holding member for holding the plural bus bars in one electrode line of the plural battery cells, a second holding member for holding the plural bus bars in the other electrode line of the plural battery cells, and a joining member for structurally joining the first holding member to the second holding member. The joining member is formed in an arch shape upwardly projected from inside ends of the first holding member and the second holding member. The joining member has a rigid part adapted to maintain the arch shape and a flexible part adapted to vertically bend by a load from above.