Universal Bus Bar Holding Module for Battery Packs

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Solution Overview

Problem

Existing external connection bus bar systems require multiple types of bus bars and insulating protectors for different power storage element configurations, leading to labor-intensive attachment processes and increased costs due to the need for various molds for different power storage element group arrangements.

Innovation Solution

An external connection bus bar holding module comprising three protector portions - a first protector portion, a second protector portion, and an intermediate protector portion - that can be adapted to any power extraction position, allowing for easy attachment and reduced mold requirements by using a single mold for the intermediate protector portion, which can be easily lengthened or shortened based on the number of power storage elements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple types of external connection bus bars with different shapes are used to adapt to different power extraction positions, then adaptability is improved, but device complexity and manufacturing cost increase due to needing multiple types of insulating protectors and molds

Engineering Contradiction:

Improveadaptability to power extraction positionVSAvoidnumber of bus bar types and protector types

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies universality by designing a single type of insulating protector that can accommodate external connection bus bars of different lengths and configurations. The protector includes a body portion and a cover portion that can adapt to various bus bar shapes without requiring different protector types, thereby reducing device complexity while maintaining adaptability to different power extraction positions

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The insulating protector is segmented into a body portion and a cover portion that can be separately assembled. This segmentation allows the protector to adapt to different bus bar configurations by combining these portions in various ways, reducing the need for multiple complete protector types while maintaining versatility

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If multiple types of insulating protectors are separately attached to hold different bus bar configurations, then adaptability is improved, but labor intensity increases due to separate attachment requirements

Engineering Contradiction:

Improveadaptability to bus bar configurationVSAvoidattachment labor intensity

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The patent merges the body portion and cover portion of the insulating protector into a single integrated component that can be attached as one unit. This unified structure eliminates the need to separately attach multiple different protector types, significantly reducing attachment labor while maintaining the ability to adapt to various bus bar configurations through the design flexibility of the single protector type

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If different shaped bus bars are used to reach various power extraction positions, then adaptability is improved, but manufacturing cost increases due to multiple mold requirements

Engineering Contradiction:

Improvecoverage of power extraction positionsVSAvoidmold quantity and manufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent applies universality by designing a single-type insulating protector that serves multiple functions across different power extraction positions. This single protector design eliminates the need for multiple specialized molds, reducing manufacturing complexity and cost while maintaining the ability to accommodate various bus bar configurations through its adaptable structure

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS10720627B2External connection bus bar holding module and battery connection module

Publication Date: 2020.07.21 AUTONETWORKS TECH LTD

AI summary

An external connection bus bar holding module includes: a first external connection bus bar, a second external connection bus bar, a first protector portion that holds a first electrode connection portion of the first external connection bus bar, a second protector portion that is arranged at an interval from the first protector portion and holds the first external connection portion of the first external connection bus bar, and an intermediate protector portion. The intermediate protector portion is located between the first protector portion and the second protector portion and holds an intermediate portion of the first external connection bus bar between the first protector portion and the second protector portion.