Segmented Bus Bar with Elastic Bend Portions for Battery Modules
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Solution Overview
Problem
Conventional bus bars face challenges in maintaining low electrical resistance, flexibility, and positional accuracy while avoiding gaps between terminal connecting parts due to manufacturing counterforces, which complicates assembly and increases manufacturing costs.
Innovation Solution
A bus bar design featuring a block-shaped thick portion with thin portions and elastically deformable bend portions that connect the thick and thin sections, allowing for easy soldering or welding and reducing bending moments, thereby preventing misalignment and facilitating manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bus bar uses a thick plank to suppress electrical resistance, then electrical resistance is reduced, but flexibility is compromised
Solution Approach 1:
The bus bar is divided into multiple sections with different thicknesses: a thick portion for low electrical resistance and thin portions for flexibility. This segmentation allows each section to fulfill its specific functional requirement independently.
Solution Approach 2:
Different portions of the bus bar have different thickness properties tailored to their specific functions. The thick portion provides low electrical resistance where current flows, while thin portions provide flexibility for positioning and absorbing thermal expansion.
2Adaptability or versatility
If an arcuate bend part is provided to maintain flexibility, then flexibility is improved, but manufacturing precision deteriorates due to gaps between terminals and terminal connecting parts
Solution Approach 1:
The bus bar structure separates the bending function (in thin portions) from the connection function (in thick terminal connecting parts), ensuring that bending occurs in controlled areas without affecting terminal positioning accuracy.
Solution Approach 2:
The thin portions are designed to elastically deform and absorb counterforces from terminals during manufacturing, preventing gaps from forming between terminals and terminal connecting parts before welding occurs.
3Ease of manufacture
If the bus bar structure is simplified for easy manufacturing, then ease of manufacture is improved, but manufacturing precision deteriorates due to gaps from counterforce
Solution Approach 1:
The bus bar is segmented into thick and thin portions that can be formed through simple stamping or extrusion processes, maintaining manufacturing simplicity while the thin portions naturally compensate for manufacturing counterforces through elastic deformation.
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 design achieves low electrical resistance, flexibility, and heat management while ensuring precise positional accuracy and ease of manufacturing, reducing the likelihood of gaps between terminals and improving assembly quality.
Implementation Method 1
two bend portions that connect the thick portion and the thin portions, the connected thick portion and the thin portions being elastically deformable
Data Source
AI summary
A bus bar according to an embodiment includes a block-shape thick portion, two thin portions provided along the thick portion on both sides, and two bend portions that connect the thick portion and the thin portions, the connected thick portion and the thin portions being elastically deformable.