Integrated Bus Bar Assembly for Compact Battery Modules
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Solution Overview
Problem
Existing battery module assemblies face challenges with complex assembly processes, increased size, and reduced stability due to the need for multiple mechanical and electrical connection members, as well as complications in sensing and controlling overvoltage, overcurrent, and overheating, especially as capacity increases.
Innovation Solution
A bus bar assembly with a modular structure featuring a cover plate, conductive connection parts, and bus bars that are easily expandable, allowing for compact electrical connections and simplified assembly, with integrated sensing members for voltage measurement, and a supporting structure that enhances stability against external forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple mechanical fastening and electrical connection members are used to connect battery cells, then reliable electrical connection is achieved, but the assembly process becomes very complicated
Solution Approach 1:
The patent combines mechanical fastening and electrical connection functions into a single integrated bus bar structure. The bus bar simultaneously provides structural support and electrical connectivity, eliminating the need for separate mechanical fasteners and electrical connectors, thus simplifying the assembly process while maintaining connection reliability
Solution Approach 2:
The bus bar is designed as a multi-functional component that performs multiple roles: it serves as an electrical conductor for current flow, a mechanical fastener for securing battery cells, and a structural support element. This universal design reduces the total number of components needed in the battery assembly
2Stability of the object's composition
If multiple connection members are used for mechanical fastening and electrical connection, then stable structure is achieved, but the overall size of the battery system increases
Solution Approach 1:
By merging mechanical fastening and electrical connection into a single bus bar component, the patent eliminates the space required for multiple separate members. The integrated design reduces the overall volume occupied by connection hardware while maintaining structural stability through the bus bar's optimized geometry
3Power
If a plurality of battery cells are electrically connected in series or parallel to increase capacity, then power and capacity requirements are met, but the assembly process becomes very complicated
Solution Approach 1:
The patent employs modular bus bar designs that can be systematically configured for series or parallel connections. Each bus bar module follows a standardized design pattern, allowing scalable assembly for different power and capacity requirements without proportionally increasing assembly complexity
Solution Approach 2:
The universal bus bar design can be adapted for both series and parallel electrical connections through standardized configurations. This multi-functionality allows the same basic component design to serve multiple connection topologies, simplifying the assembly process across different battery capacity requirements
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 enables a compact, stable, and easily expandable battery module assembly with improved assembly efficiency, reduced risk of short circuits, and enhanced structural stability, allowing for increased capacity without increasing the overall size or complexity.
Implementation Method 1
two or more bus bars mounted at the upper end of the cover plate in a direction perpendicular to a direction in which the cell module assemblies are arranged to electrically connect the conductive connection parts of the cell module assemblies to each other
Implementation Method 2
the cover plate is provided at a front and a rear thereof with through holes, through which a supporting bar to support the cell module assemblies is inserted
Data Source
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AI summary
Disclosed herein is a bus bar assembly to electrically two or more cell module assemblies such that the cell module assemblies are arranged in a lateral direction in a state in which the cell module assemblies are in tight contact with each other or adjacent to each other to constitute a battery module assembly, the bus bar assembly including (a) a cover plate made of an electrically insulative material, the cover plate being mounted at upper ends of the cell module assemblies, (b) two or more conductive connection parts electrically connected to external input and output terminals of the cell module assemblies in a state in which the conductive connection parts are mounted on the cover plate, and (c) two or more bus bars mounted at the upper end of the cover plate in a direction perpendicular to a direction in which the cell module assemblies are arranged to electrically connect the conductive connection parts of the cell module assemblies to each other.