Bus Bar-ICB Wire Bonding Structure Against Vibration Breakage
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Solution Overview
Problem
Existing battery modules face issues with wire breakage due to external impact or vibration, particularly in the connection between bus bar plates and ICB assemblies, which complicates assembly and hinders structural simplification.
Innovation Solution
A battery module design that integrates bus bar plates and ICB assemblies with overlapping ends fixed by adhesive, using 'U'-shaped rabbit ear parts and integrated pin structures to prevent relative movement, ensuring stable electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire bonding technology is used to connect bus bar plate and voltage sensing component, then electrical connection is achieved, but wire breakage risk increases under external impact or vibration
Solution Approach 1:
The patent introduces a reinforcing structure (metal plate or bus bar) as an intermediary between the voltage sensing component and the bus bar plate. This intermediary provides mechanical support and distributes external forces, preventing direct stress on the wire bonding connection and eliminating the wire breakage risk from external impact or vibration.
2Reliability
If cable connector with welding/bolting/riveting is used for voltage sensing, then reliable electrical connection is achieved, but assembly time increases and structure becomes complex
Solution Approach 1:
The patent merges the voltage sensing component directly with the bus bar plate by positioning them adjacent to each other and reinforcing their connection with a metal plate. This integration eliminates the need for separate cable connectors, welding, bolting, or riveting processes, significantly reducing assembly time while maintaining reliable electrical connection through the reinforced structural bond.
3Ease of manufacture
If bus bar plate and ICB assembly are loosely connected, then assembly is simple, but relative movement occurs under external impact causing wire disconnection
Solution Approach 1:
The patent applies preliminary action by pre-positioning the bus bar plate and ICB assembly in their final adjacent positions during the manufacturing process, and reinforcing their connection with a metal plate before the product reaches the customer. This preliminary structural reinforcement prevents any relative movement from occurring during subsequent use, eliminating wire disconnection risks while maintaining assembly simplicity.
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 design enhances electrical connection rigidity, simplifies wiring, and reduces the risk of wire breakage, thereby improving the reliability and efficiency of the assembly process.
Implementation Method 1
each of the bus bar plates (300) and each of the sensing plates (410) have portions that overlap partially in an up-down direction and are integrally fixed to each other so as not to move relative to each other, and is electrically connected by a conductive wire
Data Source
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AI summary
A battery module according to the present disclosure includes battery cells having a battery can and a top cap coupled to the battery can; a cell frame provided to accommodate and fix the battery cells therein; bus bar plates spaced apart from each other and disposed on an outer side of the cell frame and electrically connected to the battery cells; and an inter connection board (ICB) assembly having sensing plates electrically connected to the bus bar plates, respectively, and mounted on the other outer side of the cell frame, wherein each of the bus bar plates and each of the sensing plates have portions that overlap vertically and are fixed so as not to move relative to each other, and are electrically connected by a conductive wire.