Bus Bar Assembly with Movable Conductors for Battery Module
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Solution Overview
Problem
Conventional bus bar assemblies require manual bending and alignment of electrode leads, which is labor-intensive and results in poor adhesion due to the elastic restoration force of metal electrode leads, especially when connecting multiple leads in parallel.
Innovation Solution
A bus bar assembly featuring a fixed rod-shaped conductor with movable bus bars and an adhering member, such as a leaf spring, that allows electrode leads to be inserted and mechanically compressed without bending, ensuring reliable electrical and mechanical bonding through a fitting space mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If electrode leads are bent manually to align with bus bar, then alignment is achieved, but labor intensity increases and adhesion reliability deteriorates due to elastic restoration force
Solution Approach 1:
The bus bar is designed with a movable portion that can move in the longitudinal direction, transforming from a static structure to a dynamic one. This allows the bus bar to adapt to the electrode lead position automatically, eliminating the need for manual bending while maintaining reliable adhesion through controlled movement rather than elastic deformation
Solution Approach 2:
The movable portion acts as an intermediary mechanism between the electrode lead and the fixed portion of the bus bar. It mediates the connection by providing a controlled movement interface that facilitates alignment without requiring manual bending, thereby improving both ease of operation and adhesion reliability
2Quantity of substance
If multiple electrode leads are connected in parallel, then electrical capacity increases, but welding difficulty increases and welding quality deteriorates
Solution Approach 1:
The movable portion enables dynamic adjustment that accommodates multiple electrode leads simultaneously. By allowing controlled movement, it facilitates the welding process for multiple leads in parallel without increasing welding difficulty, as the movable structure can adapt to the collective positioning requirements of multiple leads
3Reliability
If electrode leads are made of metal material for electrical conductivity, then electrical performance improves, but elastic restoration force increases causing poor adhesion
Solution Approach 1:
The movable portion provides a dynamic connection mechanism that compensates for the elastic restoration force of metal electrode leads. Instead of relying on rigid fixed connections that suffer from elastic rebound, the movable structure allows controlled movement that maintains continuous electrical contact while accommodating the metal's elastic properties, thereby preserving both electrical reliability and mechanical adhesion
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
Eliminates the need for manual bending, improves the reliability of electrical connections and mechanical bonding strength, and enhances automation in battery module production by allowing secure welding of electrode leads in a compressed state.
Implementation Method 1
an adhering member configured to move the pair of movable bus bars closer to the fixed bus bar when an electrode lead is located in each fitting space so that the electrode leads can be adhered to the fixed bus bar
Data Source
AI summary
A bus bar assembly for electrically connecting a plurality of battery cells having electrode leads includes a fixed bus bar provided in the form of a rod-shaped conductor; a pair of movable bus bars disposed to be spaced from both sides of the fixed bus bar in a lateral direction with the fixed bus bar being interposed therebetween to form a fitting space respectively between the pair of movable bus bars and the fixed bus bar so that at least one electrode lead can be inserted therein; and an adhering member configured to move the pair of movable bus bars close to the fixed bus bar when an electrode lead is located in each fitting space so that the electrode leads can be adhered to the fixed bus bar.