Insulated Connection Module for Bus Bar Safety
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Solution Overview
Problem
In power storage devices, operators risk touching exposed metal portions of bus bars when connecting them, leading to safety hazards and increased electrical resistance.
Innovation Solution
A connection module with a housing case made of insulating material, featuring a fastening member with a bolt and nut configuration, where the bolt's head is covered by an insulation member, and an elastic member to ensure secure electrical connection while preventing direct contact with metal parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the bus bar end portions are exposed for connection, then the connection operation is simplified, but the operator may touch the metal portions causing safety hazards and increased electrical resistance
Solution Approach 1:
An insulation member is introduced as an intermediary component between the operator and the metal bus bar. The insulation member covers the metal portion of the bus bar that is visible through the tool insertion hole, allowing operators to perform connection operations without direct contact with conductive surfaces, thereby eliminating safety hazards and electrical resistance issues while maintaining operational ease
Solution Approach 2:
The insulation member is selectively positioned only at the specific location where the bus bar end is visible through the tool insertion hole. This localized insulation approach provides protection exactly where needed during connection operations, without requiring complete insulation of the entire bus bar structure, thus maintaining ease of operation while addressing the safety hazard
2Object-affected harmful factors
If the insulation member is added to cover the bus bar, then operator safety is improved, but the device complexity increases
Solution Approach 1:
The insulation member is merged with the existing bus bar structure, forming an integrated component where the insulation layer is applied directly to the bus bar. This combination approach adds the safety function without requiring a completely separate insulation system, thereby minimizing the increase in device complexity while effectively preventing operator contact with metal
3Object-affected harmful factors
If the bus bar is fully insulated, then operator safety is maximized, but the connection operation becomes difficult
Solution Approach 1:
The insulation is applied locally only to the portion of the bus bar that is visible through the tool insertion hole during connection operations. This selective insulation maintains operator safety by covering exposed metal surfaces while leaving other portions accessible, thereby preventing operator contact hazards without impeding the connection operation
Data Source
AI summary
A connection module includes a first bus bar, a second bus bar and a connection unit. The connection unit includes a housing case having an insulation property and having a housing space formed therein, and a fastening member disposed inside the housing space. The connection unit is provided with a tool insertion hole through which a tool to be attached to the fastening member is insertable. The fastening member is configured to electrically connect the first bus bar and the second bus bar that are disposed inside the housing space. An insulation member is disposed in a portion of the fastening member that is visible through the tool insertion hole when the fastening member is seen through the tool insertion hole.