Oblique Bus Bar Lead Geometry for Battery Pack Short-Circuit Prevention
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Solution Overview
Problem
The durability and functionality of rechargeable battery packs deteriorate due to frequent short-circuits caused by interference and incorrect insertion of bus bars during the connection process with electrode terminals.
Innovation Solution
A rechargeable battery pack design featuring bus bars located at the upper side of a holder with obliquely protruded lead parts that connect electrode terminals, utilizing through-holes in a matrix configuration to prevent misassembly and interference, and incorporating stopper and guide protrusions to stabilize the bus bar position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bus bars are arranged to connect electrode terminals of cell modules, then electrical connection is achieved, but interference and misassembly occur causing short-circuits
Solution Approach 1:
The bus bar is designed with an asymmetric structure where the body part and lead parts are positioned at different heights and angles. The lead parts obliquely protrude from the body part, creating a unique insertion orientation that prevents misassembly and interference between adjacent bus bars, thereby eliminating short-circuit hazards while ensuring reliable electrical connection
Solution Approach 2:
The bus bar transitions from a conventional flat configuration to a three-dimensional structure with the body part extending in one direction and lead parts obliquely protruding in another dimension. This dimensional change allows the lead parts to pass through corresponding through-holes in the holder part at specific angles, preventing interference while maintaining electrical connectivity
2Reliability
If bus bars are inserted to connect electrode terminals, then electrical connection is established, but incorrect insertion occurs reducing durability
Solution Approach 1:
The asymmetric design of the bus bar with obliquely protruding lead parts creates a unique insertion geometry that can only fit into the holder part in the correct orientation. This prevents incorrect insertion that would compromise connection quality and reduce battery pack durability over time
Solution Approach 2:
The bus bar is pre-configured with lead parts protruding at specific angles (45-60 degrees) from the body part, establishing the correct insertion orientation before assembly. The corresponding through-holes in the holder part are pre-positioned to receive these lead parts, ensuring proper alignment and preventing incorrect insertion during assembly
3Temperature
If cell modules are obliquely arranged to dissipate heat, then thermal management is improved, but bus bar arrangement becomes complex
Solution Approach 1:
The bus bar adopts a three-dimensional configuration with the body part extending parallel to cell module arrangement and lead parts obliquely protruding at angles that correspond to the oblique arrangement of cell modules. This dimensional adaptation allows the bus bar to accommodate the thermal management layout while maintaining a systematic and manageable structure
Data Source
AI summary
A rechargeable battery pack includes: a battery housing having an accommodation space; a plurality of cell modules in the accommodation space an having a plurality of unit battery cells connected to each other, and obliquely arranged; a holder part supporting the cell module inside the battery housing; and a bus bar at an upper side of the holder part and connecting electrode terminals of the unit battery cells, wherein the bus bar is between the cell modules at the upper side of the holder, and a lead part connected to the electrode terminal is obliquely protruded from at least one side of the bus bar.