Insulated Bus Bar Coating for Heat-Resistant Battery Connections
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Solution Overview
Problem
Existing methods for producing a battery cell connection technologies fail to solve the problem of providing a battery cell connection technologies that are not able to efficiently connect battery cells with a bus bar that are not able to efficiently connect battery cells with each other by a bus bar that are not able to connect battery cells with each other by a bus bar that are not able to connect battery cells with each other by a bus bar that are not able to connect battery modules with each other by a bus bar that are not able to connect battery cells with each other by a bus that are not capable of connecting with a bus that are not able to connect with a bus that can communicate with a bus that are not designed to ensure insulation and heat resistance in abnormal states, especially when the bus bar has a complicated shape or when the mica sheet peels off.
Innovation Solution
A bus bar with a conductive body covered by an insulating film, where the film has varying thickness ratios and includes a filler compound that includes a silicate compound, preferably contains a filler, which includes a silicate compound and a silicate compound, and a silicone-based material, produced by dip coating to ensure insulation and heat resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of the coating film is increased to ensure heat resistance and insulation property, then the heat resistance and insulation property are improved, but the material cost of the coating film increases
Solution Approach 1:
The patent applies local quality by forming a coating film with non-uniform thickness where the film thickness is increased at specific locations (edges and corners of the bus bar body) that require higher insulation and heat resistance, while maintaining thinner film at other locations to reduce material cost. This resolves the contradiction by optimizing material distribution according to actual performance requirements.
2Reliability
If a mica sheet is used to cover the bus bar body, then heat resistance and insulation property are improved, but the device complexity increases due to winding operation requirements
Solution Approach 1:
The patent replaces the mechanical winding operation of mica sheets with a coating process that forms an insulating film directly on the bus bar body. This substitution eliminates the complexity of winding operations while maintaining the heat resistance and insulation properties, as the coating film is applied uniformly and adheres firmly to the bus bar surface.
3Reliability
If a coating film is formed on the bus bar body, then insulation property is improved, but the coating film may be damaged in abnormal states such as explosion or thermal runaway
Solution Approach 1:
The patent employs composite materials by combining the bus bar body (aluminum or copper) with a coating film having specific properties (heat resistance, insulation, and adhesion). This composite structure provides both the electrical conductivity of the metal bus bar and the protective insulation and heat resistance of the coating film, while the firm adhesion ensures the film remains intact during abnormal conditions.
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 bus bar provides stable insulation and heat resistance, preventing peeling and ensuring high safety in abnormal states, while reducing material costs and simplifying production, even with complex shapes.
Implementation Method 1
a dipping step of immersing the bus bar body in an insulating coating material and then pulling up the bus bar body; and a drying step of drying the insulating coating material applied to a surface of the bus bar body to form the insulating film
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
To provide a bus bar that can be produced at a low cost and that can stably ensure an insulation property. A bus bar (1a) for use in a power storage device including a battery cell includes a bus bar body (25) containing a conductive material and having a plurality of main surfaces (a first main surface (25a) and a second main surface (25b)) orthogonal to a plate-thickness direction (27), and an insulating film (26) covering the bus bar body (25). A predetermined first main surface (25a) among the plurality of main surfaces of the bus bar body (25) has a first region (21) in which the insulating film (26) formed on the first main surface (25a) has a maximum film thickness T1max and a second region (22) in which the insulating film (26) formed on the first main surface (25a) has a minimum film thickness T1min. A ratio (T1max/T1min) of the maximum film thickness T1max to the minimum film thickness T1min is larger than 1.0 and 7.0 or less.