External Bridge Bus Bar Layout for Shock-Safe Battery Modules
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Solution Overview
Problem
High-voltage battery modules pose a significant risk of electrical shock to workers during manufacture and transportation due to increased current flow, which can lead to muscle stiffness and inability to escape, necessitating a safety enhancement to minimize these dangers.
Innovation Solution
The battery module design includes a bridge bus bar that electrically connects separated bus bars only after electricity is supplied, dividing the electrical connection into two parts to reduce voltage exposure, and features a bus bar frame and mono frame configuration within a quadrangular pipe structure for protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high-voltage battery module is used to provide required output and capacity, then power and capacity requirements are met, but risk of electrical shock to workers increases
Solution Approach 1:
The bus bar structure is divided into multiple separate components (first bus bar, second bus bar, bridge bus bar) that are not electrically connected during manufacturing and transportation. The battery module's electrical connection is segmented into disconnected states, reducing voltage exposure risk while maintaining power output capability when assembled.
Solution Approach 2:
The bus bars are prepared in a disconnected state before the battery module is assembled and put into service. The bridge bus bar is designed to connect the first and second bus bars only after assembly, ensuring that workers are not exposed to high voltage during handling and installation phases.
2Power
If bus bars are electrically connected to provide current flow, then power delivery is achieved, but muscle stiffness and inability to escape occur during electrical shock
Solution Approach 1:
The electrical connection path is segmented into separate bus bar components that are not connected during manufacturing and transportation. By dividing the conductive path into disconnected segments, the system prevents harmful current flow through human bodies while maintaining the ability to deliver required current when properly assembled.
3Ease of manufacture
If conventional bus bar structure is used, then manufacturing is simple, but electrical connection cannot be divided into separate parts for safety
Solution Approach 1:
The bus bar system is segmented into multiple separate components (first bus bar, second bus bar, bridge bus bar) that can be manufactured independently using conventional processes. The segmentation is achieved through separate manufacturing of bus bar components that are subsequently assembled, maintaining manufacturing simplicity while enabling safety through divided electrical connections.
Solution Approach 2:
The bridge bus bar acts as an intermediary component that connects the first and second bus bars only after assembly. This intermediary element enables the division of electrical connections into separate parts for safety while maintaining the overall functionality of the bus bar system through its mediating connection role.
Data Source
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AI summary
Disclosed herein is a high-voltage battery module including a bridge bus bar configured to be exposed to the outside in order to reduce a danger of accident due to electric shock when handing the high-voltage battery module, wherein a cell assembly is temporarily electrically open-circuited and the bridge bus bar is connected only when the battery module is used. It is possible to remove dangerous factors that may injure the human body during manufacture and transportation of the high-voltage battery module and to use the high-voltage battery module in the state in which restrictions are minimized.