Detachable Bus Bar Frame for Thermally Isolated Battery Modules
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Solution Overview
Problem
Existing battery modules face challenges in manufacturing efficiency due to complex bus bar coupling processes and lack of effective insulation and separation mechanisms, which can lead to heat transfer and fire propagation between battery cells.
Innovation Solution
A battery module design featuring a bus bar assembly with a detachable frame and external bus bars that maintain insulation distance and separate from battery cells under predetermined conditions, using a resin material with a melting point to prevent overheating and electrical damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If bus bars are coupled to battery cells using general methods, then electrical connectivity is achieved, but manufacturing complexity and time increase significantly
Solution Approach 1:
The bus bar assembly is divided into multiple separate bus bars instead of using a single integrated structure. Each bus bar can be independently positioned and connected to specific battery cells, simplifying the coupling process and enabling parallel assembly operations that improve manufacturing efficiency
Solution Approach 2:
A detachable frame structure serves as an intermediary component that holds and positions multiple bus bars. This frame facilitates the assembly process by providing a pre-configured structure that can be attached to battery cells as a unit, reducing the complexity of individual bus bar coupling operations
2Reliability
If bus bars are closely coupled to battery cells for electrical connection, then electrical connectivity is improved, but heat transfer and fire propagation risk increase
Solution Approach 1:
The bus bar assembly is designed to be detachably mounted on battery cells rather than permanently fixed. This extraction capability allows the bus bar assembly to be separated from battery cells under predetermined conditions (such as overheating), preventing heat and fire propagation while maintaining electrical connectivity during normal operation
Solution Approach 2:
The coupling between bus bars and battery cells is made dynamic rather than static. The detachable frame structure enables the system to transition between connected and separated states based on thermal conditions, allowing the structure to adapt to changing operational conditions and prevent harmful heat transfer when needed
3Stability of the object's composition
If bus bar assembly is permanently fixed to battery cells, then structural stability is improved, but thermal separation capability is lost
Solution Approach 1:
The coupling mechanism transitions from a static permanent fixation to a dynamic detachable connection. The detachable frame structure maintains stable electrical connectivity during normal operation while enabling thermal separation when predetermined conditions are met, providing both structural stability and adaptive thermal management
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 improves manufacturing efficiency, enhances stability by preventing heat and fire spread, and maintains electrical connectivity while ensuring safety through thermal separation and insulation.
Implementation Method 1
using a resin material with a melting point to prevent overheating and electrical damage
Data Source
AI summary
A battery module is disclosed. The battery module includes a plurality of sub-modules each including at least one battery cell and an internal bus bar electrically connected to an electrode tab of the at least one battery cell, and a bus bar assembly configured to connect the internal bus bars of the plurality of sub-modules. The bus bar assembly includes a bus bar frame detachably mounted on the plurality of sub-modules, and an external bus bar coupled to the bus bar frame and configured to electrically connect sub-modules adjacent to each other among the plurality of sub-modules.