Insulated Bus Bar Assembly for Compact Battery Modules

Solution Overview

Problem

Existing battery systems face challenges with increased weight, complex assembly processes, and reduced energy density due to the use of plastic harness isolation plates between bus bars, which complicate production and increase costs.

Innovation Solution

A bus bar design with integrated insulating layers and substrates eliminates the need for plastic harness isolation plates, allowing for compact arrangement of battery cells and direct connection to a Battery Management System (BMS) without Flexible Printed Circuit (FPC)/Flexible Flat Cable (FFC), reducing weight and internal space usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a plastic harness isolation plate with reinforcing ribs is added between two adjacent bus bars to ensure insulation and withstand voltage, then the insulation and withstand voltage requirements are met, but the weight of the battery system increases

Engineering Contradiction:

Improveinsulation and withstand voltageVSAvoidweight of battery system

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The insulating layer is integrated directly onto the surface of the bus bar connection parts and substrates, merging the insulation function with the structural components themselves. This eliminates the need for separate plastic harness isolation plates, thereby reducing weight while maintaining insulation and withstand voltage requirements.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The bus bar structure combines conductive materials (for electrical connection) with insulating materials (coated as insulating layers on the surface), creating a composite structure that simultaneously achieves electrical conductivity where needed and insulation where required, without needing separate plastic components.

Inventive Principle:

Principle #40Composite materials

2Reliability

If a plastic harness isolation plate with reinforcing ribs is added between two adjacent bus bars, then the insulation and withstand voltage requirements are met, but the internal space utilization of the battery system is reduced

Engineering Contradiction:

Improveinsulation and withstand voltageVSAvoidinternal space of battery system

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The insulating layer is integrated directly onto the surface of the bus bar connection parts and substrates, merging the insulation function with the structural components themselves. This eliminates the need for separate plastic harness isolation plates, thereby reducing weight while maintaining insulation and withstand voltage requirements.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The insulating layer is applied as a thin film coating on the bus bar surfaces, providing the necessary insulation and withstand voltage protection while occupying minimal space. This thin-film approach allows for compact battery cell arrangement without the bulk of traditional plastic isolation plates.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If a plastic wiring harness isolation plate is added, then the insulation and withstand voltage requirements are met, but the production and assembly processes become complicated and production cost increases

Engineering Contradiction:

Improveinsulation and withstand voltageVSAvoidproduction and assembly process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The insulating layer is integrated directly onto the surface of the bus bar connection parts and substrates, merging the insulation function with the structural components themselves. This eliminates the need for separate plastic harness isolation plates, thereby reducing weight while maintaining insulation and withstand voltage requirements.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The bus bar structure itself provides the insulation function through the insulating layers on its surfaces, making the component self-sufficient for both electrical connection and insulation purposes. This self-service approach eliminates the need for additional isolation plates and simplifies both production and assembly processes.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS12525688B2Bus bar, battery cell acquisition assembly and battery module

Publication Date: 2026.01.13 EVE POWER CO LTD

AI summary

The application discloses a bus bar, a battery cell acquisition assembly and a battery module. The bus bar is arranged to electrically connect a plurality of battery cells to form a battery cell group, and comprises a plurality of bus bar main bodies and at least one substrate. Each bus main body includes a positive conductive part and a negative conductive part, the connection part is electrically connected with the positive electrode of one battery cell, the negative connection part is electrically connected with the negative electrode of another battery cell, the positive conductive part and the negative conductive part are electrically connected through the connection part, and the surface of the connection part is provided with an insulating layer. Two adjacent bus bar main bodies are electrically connected through a substrate, and the surface of each substrate is provided with an insulating layer.