Multi-Function Bus Bar for Battery Module Voltage Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery modules face challenges in simultaneously achieving electrical connection and voltage detection between unit cells without causing short circuits, while also requiring additional components for connecting to a battery management system, leading to mechanical weakness and increased size.
Innovation Solution
A bus bar with vertically bent parts and a horizontal bent part is used for both electrical connection and voltage detection, eliminating the need for additional connecting members and allowing direct connection to a battery management system, thereby enhancing mechanical strength and reducing module size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additional connecting members are used for voltage detection, then voltage detection capability is improved, but device complexity and size increase
Solution Approach 1:
The bus bar is designed to perform multiple functions: electrical connection between unit cells and voltage detection to the BMS. The same bus bar structure provides both current conduction and voltage sensing capabilities, eliminating the need for separate connecting members for each function.
Solution Approach 2:
The invention merges the electrical connection function and voltage detection function into a single bus bar component. The bus bar simultaneously serves as the electrical connector between unit cells and the voltage detection point for the BMS, reducing the total number of components.
2Adaptability or versatility
If additional connecting members are used for voltage detection, then voltage detection capability is improved, but mechanical strength decreases
Solution Approach 1:
The bus bar performs both electrical connection and voltage detection functions, eliminating the need for additional weak connecting members. The single bus bar structure maintains mechanical integrity while providing both electrical and sensing functions.
3Reliability
If conventional electrical connection methods are used, then electrical connection is achieved, but contact resistance increases due to corrosion
Solution Approach 1:
The bus bar is made of aluminum alloy material that provides both electrical conductivity and corrosion resistance. The specific aluminum alloy composition and surface treatment enhance resistance to corrosion, preventing contact resistance increase over time while maintaining reliable electrical connection.
4Volume of moving object
If compact structure is implemented, then module size is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The bus bar is designed with segmented functional zones: vertical bent parts for electrical connection to unit cells, horizontal bent parts for voltage detection to BMS, and coupling grooves/protrusions for precise positioning. This segmentation allows each zone to be optimized for its specific function while maintaining overall compactness.
Solution Approach 2:
Different portions of the bus bar have different geometries optimized for their specific functions: vertical bends for connection, horizontal bends for detection, and coupling features for positioning. This local optimization enables compact design without compromising manufacturing precision.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Disclosed herein are a bus bar that simultaneously performs the electrical connection between a plurality of unit cells and the detection of voltage of the unit cells in a battery module having the unit cells mounted therein, wherein the bus bar includes: vertical bent parts formed by bending opposite ends of a strip-shaped bar body in the same direction, respectively, the vertical bent parts being provided with coupling grooves or protrusions; and a horizontal bent part formed by bending one of the vertical bent parts such that the horizontal bent part is parallel with the bar body, and a medium- or large-sized battery module including a plurality of unit cells, wherein the electrical connection between the unit cells and the detection of voltage of the unit cells are simultaneously performed using the bus bar.