Battery Module Busbar Bushing for Simplified Voltage and Temperature Sensing
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Solution Overview
Problem
Existing battery management systems require complex assemblies for acquiring key information from battery cells, involving high-voltage cables and flex prints that need mounting and welding, leading to inefficient and costly connections.
Innovation Solution
A battery module design incorporating a thermally and electrically conductive bushing that connects busbars to a circuit board, allowing for direct electrical and thermal contact without additional components, using a fixation element to space the circuit board from the busbar, thereby simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-voltage cables and flex prints are used to connect battery cells to the management system, then electrical and thermal monitoring is achieved, but assembly complexity and manufacturing cost increase
Solution Approach 1:
The patent combines electrical connection and thermal monitoring functions into a single bushing component. The bushing simultaneously provides electrical conductivity for voltage monitoring and thermal conductivity for temperature sensing, eliminating the need for separate high-voltage cables and flex prints. This merging of functions directly reduces assembly complexity while maintaining monitoring accuracy.
Solution Approach 2:
The bushing serves multiple functions: electrical connection, thermal conduction, and mechanical support. By making the bushing multi-functional, the patent eliminates the need for additional specialized components like dedicated temperature sensors and high-voltage cables, thereby simplifying the overall assembly process and reducing manufacturing steps.
2Ease of manufacture
If multiple separate components are used for electrical and thermal connections, then functional requirements are met, but manufacturing cost and assembly time increase
Solution Approach 1:
The patent merges multiple separate components (electrical cables, temperature sensors, mounting brackets) into a single integrated bushing. This reduction in component quantity directly lowers manufacturing costs by reducing the number of parts that need to be produced, procured, and managed in the supply chain.
Solution Approach 2:
The bushing is designed as a universal component that performs electrical connection, thermal conduction, and mechanical support functions. This multi-functionality eliminates the need for multiple specialized components, thereby reducing the total number of parts and simplifying inventory management and assembly operations.
3Reliability
If additional mounting and welding components are used, then secure electrical connections are achieved, but production time and cost increase
Solution Approach 1:
The bushing integrates electrical connection and thermal monitoring in a single component that requires only insertion and fixation, eliminating the need for separate welding operations and multiple mounting steps. This integration maintains connection reliability while dramatically reducing assembly time and increasing production speed.
Solution Approach 2:
The patent extracts the complex welding and mounting operations from the assembly process by designing the bushing to provide all necessary connections through simple insertion and fixation. This extraction of complex manufacturing steps directly increases assembly speed while maintaining connection reliability through the bushing's integrated design.
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 enables efficient, cost-effective, and accurate measurement of battery cell voltages and temperatures by eliminating the need for additional components, reducing assembly complexity and improving thermal isolation, thus enhancing the reliability and efficiency of battery management.
Implementation Method 1
a thermally and electrically conductive bushing thermally and electrically connected to the busbar
Implementation Method 2
a thermally and electrically conductive bushing thermally and electrically connected to the busbar
Data Source
AI summary
A battery module includes: a plurality of battery cells; a busbar contacting the plurality of battery cells; a thermally and electrically conductive bushing thermally and electrically connected to the busbar; and a circuit board fixed to the bushing by a fixation element such that the bushing spaces the circuit board from the busbar. The circuit board includes: a temperature sensor in thermal contact with the busbar through the bushing; and a voltage signal line in electrical contact with the busbar through the bushing.