Integrated Bus Bar Assembly for Flexible Battery Cell Circuits
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Solution Overview
Problem
Conventional methods for connecting electrode leads of battery cells require complex processes involving multiple components of varying forms, complicating the construction of circuits.
Innovation Solution
A bus bar assembly comprising a frame, sensing bus bars, inter bus bars, and terminal bus bars, formed through an insert injection process, allowing for the construction of various circuits using unified components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple components of varying forms are used to construct circuits connecting electrode leads, then the circuits can be constructed, but the construction process becomes complicated
Solution Approach 1:
The bus bar assembly is designed with multi-functional capabilities to perform various circuit connections (series, parallel, and combined configurations) using a single unified component structure. The assembly includes a bus bar body with multiple connection terminals that can accommodate different electrode lead arrangements, eliminating the need for multiple specialized components for different circuit types.
Solution Approach 2:
The invention merges multiple separate components (positive bus bar, negative bus bar, connection plates, and insulators) into a single integrated bus bar assembly. The assembly combines positive and negative terminal structures, connection elements, and insulation features into one unified component that simplifies the overall construction process while maintaining circuit configuration flexibility.
2Adaptability or versatility
If multiple components of varying forms are used to construct circuits, then various circuit forms can be achieved, but the manufacturing process becomes complicated
Solution Approach 1:
The manufacturing process is simplified by combining multiple separate components into a single integrated bus bar assembly that can be manufactured as one piece or pre-assembled unit. This reduces the number of manufacturing steps, inventory management requirements, and assembly operations needed during battery production.
Solution Approach 2:
The bus bar assembly is designed as a universal component that can accommodate various circuit configurations (series, parallel, and combined) through its standardized connection terminals and flexible electrode lead insertion design, eliminating the need to manufacture different specialized components for different circuit types.
3Adaptability or versatility
If various forms of components are combined to construct circuits, then different battery cell connections can be made, but costs increase
Solution Approach 1:
The bus bar assembly serves as a universal connection component that can handle various battery cell configurations and circuit arrangements using the same standardized structure. This reduces the total number of different component types needed in the battery pack assembly.
Solution Approach 2:
The invention combines multiple separate connection components (positive bus bars, negative bus bars, connection plates, and insulators) into a single integrated assembly, reducing the total component count and associated material costs while maintaining the ability to create different battery cell connections.
Data Source
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AI summary
Disclosed is a bus bar assembly including a frame, a plurality of sensing bus bars integrally provided on the frame, an inter bus bar configured to connect any one pair of sensing bus bars, among the plurality of sensing bus bars, to each other; and a terminal bus bar configured to connect any one of the plurality of sensing bus bars to an external terminal.