Hinged Insulating Bus Bar Cover for Battery Module Safety
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Solution Overview
Problem
There is no known technique for covering bus bars with an insulating material while allowing exposure of ends during attachment and subsequent coverage to prevent short-circuits in battery modules.
Innovation Solution
An insulating bus bar cover with hinge and lid portions that can be pivoted to expose or cover the ends of the bus bar, allowing for attachment and subsequent protection from tools or interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bus bar is covered with an insulating material, then safety is improved by preventing short-circuits, but the attachment operation becomes difficult because the ends need to be exposed
Solution Approach 1:
The bus bar cover is divided into a main body portion and separate lid portions that can be independently opened at each end. This segmentation allows the ends of the bus bar to be exposed for attachment operations while the rest of the bus bar remains covered for safety, resolving the contradiction between safety and ease of operation.
Solution Approach 2:
The lid portions are designed to be movable relative to the main body portion through hinge connections, transitioning between closed (covering) and open (exposing) states. This dynamic structure enables the cover to adapt during attachment operations, allowing easy access to bus bar ends when needed while maintaining coverage for safety when not in use.
2Ease of operation
If the bus bar ends are exposed during attachment, then ease of operation is improved, but safety deteriorates due to risk of tool contact and short-circuits
Solution Approach 1:
The cover structure is segmented into a main body and separate lid portions, allowing selective exposure of only the bus bar ends needed for attachment while keeping the rest of the bus bar covered. This minimizes the exposed conductive surfaces, reducing short-circuit risk while maintaining ease of operation.
Solution Approach 2:
The lid portions act as intermediary protective elements that can be temporarily moved aside during attachment operations and then restored to their protective position. They serve as a controllable barrier that mediates between the need for access and the need for protection, exposing only when necessary and protecting when closed.
3Reliability
If a fixed insulating cover is used, then safety is improved by preventing tool contact, but adaptability deteriorates because the ends cannot be exposed when needed
Solution Approach 1:
The bus bar cover transitions from a fixed structure to a dynamic one with movable lid portions connected by hinges. This allows the cover to adapt its configuration based on operational needs - closed for safety during storage and transport, and open during attachment operations, thereby achieving both safety and adaptability.
Solution Approach 2:
The lid portions are pre-positioned in a closed protective state but are designed to be easily opened when needed. The hinge mechanism allows for preliminary protection while enabling quick adaptation to operational requirements, combining safety with the capability for exposure when attachment is needed.
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
Enables safe and efficient attachment of bus bars between cell groups by exposing ends during attachment and covering them afterwards, preventing short-circuits and ensuring reliable electrical connections.
Implementation Method 1
hinge portions that are provided at ends of the main body portion; and lid portions that are attached via the hinge portions to the main body portion, and are pivotable by the hinge portions so as to cover or expose the ends of the bus bar
Data Source
AI summary
An insulating bus bar cover is attachable to a bus bar between cell groups, both ends of the bus bar being respectively fixable to electrode terminals having opposite polarities in order to electrically connect the electrode terminals. The bus bar cover includes a main body portion for covering the bus bar while exposing both ends of the bus bar, hinge portions that are provided at ends of the main body portion, and lid portions that are attached via the hinge portions to the main body portion, and are pivotable by the hinge portions so as to cover or expose the ends.