Integrated Conductor Track in Battery Module Cover

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Solution Overview

Problem

Existing battery module covering solutions are complex, leading to increased technical effort and risk of assembly errors, as well as exposure of high-voltage components during assembly, which poses a risk of electric shock.

Innovation Solution

Integrating a conductor track into the module cover, which is partially exposed for electrical contact points, reducing the number of parts and simplifying assembly while ensuring electrical isolation during disassembly, thus minimizing the risk of electric shocks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If separate busbar and cover are used, then electrical connection is achieved, but device complexity increases and assembly becomes complicated

Engineering Contradiction:

Improvenumber of partsVSAvoidassembly process

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The busbar is integrated directly into the cover structure, merging two previously separate components (busbar and cover) into a single unified component. This integration reduces the total number of parts and simplifies the assembly process by eliminating separate installation steps for the busbar and cover.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cover is designed to serve multiple functions: it provides mechanical protection for the battery cells and simultaneously serves as the electrical connection component (busbar). This multi-functionality eliminates the need for a separate busbar component and reduces assembly complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of operation

If high-voltage components are exposed during assembly, then electrical contact is enabled, but risk of electric shock increases

Engineering Contradiction:

Improveassembly processVSAvoidrisk of electric shock

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The busbar is pre-integrated into the cover structure before assembly begins. This preliminary integration ensures that electrical connections are established through the cover itself, eliminating the need to expose high-voltage components during the assembly process and reducing the risk of electric shock to bystanders.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The cover acts as an intermediary component that provides both mechanical protection and electrical connection functionality. By using the cover as the mediating structure that houses the busbar, high-voltage components remain enclosed and protected during assembly, reducing exposure risks while maintaining electrical connectivity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP4145609A1Covering device for a battery module

Publication Date: 2023.03.08 MAN TRUCK & BUS SE

Figure 1~2

AI summary

The invention relates to a cover device (1) for a battery module (2). The battery module (2) has several cells for storing electrical energy, preferably for storing electrical traction energy of a vehicle. The cover device (1) comprises a module cover (3) and at least one conductor track (4, 5) held and extending through the module cover (3) for electrically contacting the cells, which is partially surrounded by material of the module cover (3) and is exposed at sections that form electrical contact points (12) for the cells. The invention further relates to an energy storage device (11) comprising the cover device (1) and the battery module (2), as well as a vehicle, preferably a commercial vehicle, comprising the cover device (1).