Flat Connection Module Bus Bar Sag Prevention
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Solution Overview
Problem
Conventional flat-shaped connection modules for power storage modules sag due to the weight of metallic bus bars, making attachment difficult and potentially compromising the reliability of connections if operators touch the bus bars during handling.
Innovation Solution
A flat-shaped connection module with integrated bus bar modules and a sheet member, secured by an insulating fixing member that prevents sagging and twisting, and includes a handle portion for improved handling, along with bus bar fixing portions to secure external connection electrodes and prevent horizontal inclination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a flat-shaped connection module with metallic bus bars is used to reduce weight and simplify structure, then the structure becomes simpler and weight is reduced, but the connection module sags due to the weight of the bus bars making attachment difficult
Solution Approach 1:
The connection module is divided into multiple bus bar modules, each comprising bus bars arranged in a specific pattern and integrated with insulating sheet members. This segmentation allows each module to be independently handled and attached, reducing the sagging issue while maintaining overall structural simplicity
Solution Approach 2:
Insulating sheet members and fixing members are introduced as intermediary elements between the metallic bus bars and the power storage elements. These intermediaries provide structural support to prevent sagging, enable easier attachment, and simultaneously maintain electrical insulation, thus resolving the contradiction between simplicity and ease of operation
2Ease of operation
If operators handle the bus bars directly during attachment, then the attachment process can proceed, but the reliability of connection may be deteriorated
Solution Approach 1:
Insulating sheet members and fixing members serve as intermediary components that enable operators to handle and attach the connection module without directly touching the metallic bus bars. This maintains connection reliability by preventing contamination while still allowing easy handling through the insulating structures
Solution Approach 2:
The insulating sheet members function as thin film structures that cover and protect the bus bars, allowing operators to grasp and manipulate the connection module through the insulating material without compromising the underlying metallic components or connection reliability
Data Source
AI summary
A connection module is a flat-shaped connection module that is to be attached to a power storage element group formed by aligning a plurality of power storage elements with positive and negative electrode terminals and includes a first bus bar module, a second bus bar module, and insulating fixing members. The first and second bus bar modules include sheet members that hold the plurality of bus bars arranged in an alignment direction of the power storage elements. The fixing members are coupled to the sheet members to integrate and fix the first bus bar module and the second bus bar module.