Bus Bar Module Voltage Detection Terminal Overlap
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Solution Overview
Problem
Existing bus bar modules in battery packs face challenges in preventing temperature rise and cell deterioration due to increased resistance, which requires enlarging the bus bar's size and cost, especially in long modules with multiple cells connected in parallel.
Innovation Solution
A bus bar module design that includes an insulating resin case with a conductive metal bus bar and a voltage detection terminal, where the voltage detection terminal is strategically overlapped with the bus bar to increase the conductor cross-sectional area only at the necessary portions, preventing temperature rise without altering the bus bar's width or thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the bus bar cross-sectional area is increased to prevent heating caused by resistance, then the temperature rise is prevented, but the bus bar module is increased in size and cost
Solution Approach 1:
The voltage detection terminal is positioned to overlap specifically with the portion of the bus bar where temperature rise is most significant (the middle portion), rather than uniformly increasing the cross-sectional area along the entire bus bar length. This localized approach concentrates the additional conductor area where it is most needed to reduce resistance and prevent heating, while maintaining the original bus bar dimensions in other regions.
Solution Approach 2:
The voltage detection terminal is arranged in a direction substantially perpendicular to the bus bar's longitudinal direction, creating a stacked configuration where the terminal overlaps with the bus bar in the vertical dimension. This perpendicular arrangement allows the voltage detection function and the current conduction function to occupy different spatial dimensions, enabling the voltage detection terminal to contribute to current conduction without extending the bus bar's length.
2Temperature
If the bus bar cross-sectional area is increased to prevent heating caused by resistance, then the temperature rise is prevented, but the manufacturing cost is increased
Solution Approach 1:
The voltage detection terminal serves dual functions: it performs voltage detection by contacting the bus bar, and simultaneously acts as an additional conductor to reduce resistance and prevent heating. By making the voltage detection terminal overlap with the bus bar, the terminal material contributes to current conduction, thereby eliminating the need for separate heating prevention measures and reducing overall manufacturing cost.
Solution Approach 2:
Instead of uniformly increasing the bus bar cross-sectional area along its entire length (which would increase material consumption and cost), the invention locally increases the conductor cross-sectional area only at the middle portion where temperature rise is most significant. This is achieved by positioning the voltage detection terminal to overlap with this specific region, thereby reducing heating prevention costs where they are most needed.
3Quantity of substance
If the bus bar width or thickness is increased uniformly, then the conductor cross-sectional area is increased, but the bus bar module size is increased
Solution Approach 1:
The conductor cross-sectional area is segmented rather than uniformly distributed. The voltage detection terminal is positioned to overlap with only the middle portion of the bus bar where temperature rise is most significant, creating a non-uniform conductor cross-sectional area distribution. This segmentation allows the conductor area to be increased precisely where needed without increasing the overall bus bar module size.
Solution Approach 2:
The conductor cross-sectional area is locally increased at the middle portion of the bus bar by stacking the voltage detection terminal, rather than uniformly increasing the width or thickness along the entire bus bar length. This localized concentration of conductor material prevents heating at the critical region while maintaining compact overall dimensions.
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
This design effectively prevents temperature rise and cell deterioration by increasing the conductor cross-sectional area only where needed, reducing material usage and maintaining the bus bar's size and cost efficiency.
Implementation Method 1
The conductive metal bus bar includes a plurality of terminal through holes corresponding to a number of the positive terminal and the negative terminal. The conductive metal bus bar is accommodated in the bus bar accommodating chamber. The positive terminal and the negative terminal are collectively conducted in the conductive metal bus bar.
Implementation Method 2
the portion of the bus bar where a large amount of current flows is specified in advance, and the voltage detection terminal is attached to the bus bar so as to straddle the portion. A conductor cross-sectional area of the bus bar is increased by overlapping the voltage detection terminal therewith. As a result, the bus bar is increased in the conductor cross-sectional area, and thus temperature rise during current flowing is prevented.
Data Source
AI summary
A bus bar module includes an insulating resin case mounted to an assembled battery and including a bus bar accommodating chamber, a conductive metal bus bar, and a voltage detection terminal. The assembled battery includes a plurality of cells in which a positive terminal and a negative terminal are alternately arranged. The positive terminal and the negative terminal are collectively disposed in the bus bar accommodating chamber. The conductive metal bus bar includes a plurality of terminal through holes corresponding to a number of the positive terminal and the negative terminal. The conductive metal bus bar is accommodated in the bus bar accommodating chamber.