Bus Bar Frame Connector Holder for Flexible Battery Connections

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Solution Overview

Problem

Conventional battery modules require dedicated bus bar frames for specific electrical connections, making it difficult and costly to manufacture new models with varying shapes and connector configurations.

Innovation Solution

A battery module design featuring a unit module stack with a bus bar frame that includes a connector holder, allowing for flexible electrical connections by using connectors of various sizes and shapes, eliminating the need for dedicated bus bar frames.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If dedicated bus bar frames are used for specific electrical connections, then reliable electrical connection is achieved, but device complexity and manufacturing cost increase when developing new models

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidbus bar frame variety

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The bus bar frame is designed with multiple connector holders that can accommodate different types and sizes of connectors. This universal design allows a single bus bar frame structure to serve multiple electrical connection configurations (series, parallel, or combination), eliminating the need to develop dedicated bus bar frames for each new model while maintaining reliable electrical connections.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The bus bar frame is divided into multiple connector holders, each capable of independently accommodating different connector types. This segmentation allows flexible configuration of electrical connections by selecting and positioning appropriate connectors in different holders, enabling a single bus bar frame to adapt to various connection requirements without increasing overall device complexity.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If dedicated bus bar frames are developed for each model, then manufacturing precision for specific connections is improved, but manufacturing time and cost increase

Engineering Contradiction:

Improveconnection configuration precisionVSAvoidnew model development speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

A single standardized bus bar frame design with multiple connector holders can be used across different models, maintaining manufacturing precision through standardization while significantly improving productivity. The universal design eliminates the need to develop and manufacture new bus bar frames for each model, allowing faster new model development while preserving connection precision through consistent manufacturing processes.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The connector holders are designed to accommodate connectors of various sizes and types by changing the connector parameters rather than the bus bar frame structure. This allows different connection configurations to be achieved by selecting different connectors within the same standardized holder, maintaining manufacturing precision while enabling rapid adaptation to new model requirements.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If multiple dedicated bus bar frames are manufactured, then adaptability to different connection types is achieved, but loss of substance and resource waste occur

Engineering Contradiction:

Improveconnection type flexibilityVSAvoidbus bar frame material waste

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The bus bar frame incorporates multiple connector holders that can accommodate different connector types and configurations, providing adaptability to various connection requirements. This universal design eliminates the need to manufacture multiple dedicated bus bar frames for different connection types, thereby preventing material waste while maintaining connection flexibility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Multiple connector holders for different connection types are merged into a single bus bar frame structure. This consolidation allows the frame to provide series, parallel, or combination connections using one integrated component, reducing material consumption by eliminating the need for separate dedicated frames for each connection type.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11431063B2Battery module having structure facilitating series-parallel connections and battery pack comprising same

Publication Date: 2022.08.30 LG ENERGY SOLUTION LTD

AI summary

A battery module includes: a unit module stack formed by stacking a plurality of unit modules, each of which has a battery cell, a bus bar attached to an electrode lead provided to the battery cell, and a bus bar frame attached to a terrace portion of the battery cell to accommodate at least a portion of the electrode lead and the bus bar, wherein each bus bar frame includes a connector holder; and a connector fixed by the connector holders of at least two unit modules of the plurality of unit modules to contact the bus bar.