Battery Module Bus Bar-ICB Overlap Structure Against Wire Breakage
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Solution Overview
Problem
Existing battery modules face challenges in maintaining electrical connections and voltage sensing due to vulnerability to external impacts and vibrations, leading to potential wire breakage and assembly complexity.
Innovation Solution
A battery module design featuring bus bar plates and inter connection board (ICB) assemblies with improved assembly positions and structures, including overlapping and adhesive bonding, to enhance electrical connection rigidity and simplify assembly processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire bonding technology is used to electrically 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 bus bar plate and voltage sensing component are merged into a single integrated assembly where the sensing component is directly mounted on the bus bar plate. This eliminates separate wire connections and reduces the number of potential failure points under external impact.
Solution Approach 2:
The bus bar plate serves as an intermediary structure that provides both electrical connection and mechanical support for the voltage sensing component. This intermediary structure protects the sensing component from direct exposure to external impacts while maintaining electrical connectivity.
2Strength
If cable connector with welding, bolting, and riveting is used for electrical connection, then connection strength is improved, but assembly time increases significantly
Solution Approach 1:
The electrical connection and mechanical support functions are merged into a single integrated structure. The bus bar plate simultaneously provides electrical connectivity and structural support for the voltage sensing component, eliminating the need for separate welding, bolting, and riveting operations.
Solution Approach 2:
The bus bar plate is designed to serve multiple functions: it provides electrical connection, mechanical support, and structural protection for the voltage sensing component. This multi-functionality reduces the number of assembly steps while maintaining connection strength.
3Ease of operation
If bus bar plate and ICB assembly are loosely assembled, then assembly ease is improved, but electrical connection rigidity decreases
Solution Approach 1:
The design incorporates vertical stacking of components (bus bar plate and ICB assembly) to create overlapping regions. This dimensional arrangement provides inherent mechanical constraint and electrical rigidity while maintaining assembly simplicity through a single assembly operation.
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 solution effectively prevents wire breakage from external impacts, simplifies the wiring structure, and ensures reliable electrical connections, enhancing the overall reliability and efficiency of the battery module and pack.
Implementation Method 1
electrically connected by a conductive wire
Implementation Method 2
fixed so as not to move relative to each other
Data Source
AI summary
A battery module according to embodiments of the present disclosure may include 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 another 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.