Segmented Bus Bar Module with Deformable Holder for Battery Packs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing bus bar systems for connecting battery cells in large-capacity battery packs face challenges in adhering to electrodes with positional variations, leading to increased manufacturing complexity and cost due to the need for precise alignment and load application, which can cause damage to battery cells.
Innovation Solution
A bus bar module with deformable coupling portions and a holder that allows movable bus bars to be securely attached to electrodes, accommodating positional variations while maintaining assemblability and reducing the need for excessive load application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a long bus bar connecting electrodes of many battery cells is used, then the number of bus bars is reduced, but the load applied to the bus bar increases and may cause damage to the battery cell
Solution Approach 1:
The patent divides the long bus bar into multiple short bus bars, each connecting only two adjacent battery cells. This segmentation reduces the load on each individual bus bar while maintaining electrical connectivity across all cells. The bus bar holder integrates multiple holding portions to accommodate these segmented bus bars in an organized manner.
2Force
If the bus bar is made shorter to connect only two adjacent battery cells, then the load on the bus bar is reduced, but the manufacturing complexity and cost increase due to complicated arranging work
Solution Approach 1:
The bus bar holder serves as an intermediary component that pre-organizes multiple short bus bars in their correct positions and orientations. This intermediary structure eliminates the need for complex manual arranging during assembly, as the bus bars are already positioned within the holder before being installed onto the battery cells.
Solution Approach 2:
The bus bar holder allows bus bars to be pre-positioned and pre-assembled in a controlled manner before final installation. This preliminary action ensures correct alignment and reduces on-site assembly complexity, making the manufacturing process more efficient despite using multiple short bus bars.
3Device complexity
If a long bus bar is used to connect many battery cells, then fewer bus bars are needed, but precise alignment and load application are required which increases manufacturing complexity
Solution Approach 1:
By segmenting the long bus bar into multiple short bus bars, each connecting only two adjacent cells, the patent reduces the alignment precision required for each individual bus bar. The shorter length makes it easier to achieve proper alignment with the electrodes, reducing manufacturing complexity.
Solution Approach 2:
The bus bar holder acts as a positioning intermediary that pre-establishes the correct spatial relationships between multiple short bus bars and the battery cells. This intermediary structure guides the bus bars into proper alignment during assembly, reducing the need for high-precision manual alignment.
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 solution ensures secure adhesiveness of bus bars to electrodes with positional variations without impairing assemblability, reducing manufacturing complexity and potential damage to battery cells, while allowing for efficient collective arrangement of bus bars across multiple cells.
Implementation Method 1
a bus bar holder constituted by coupling a plurality of holding portions in a chain manner via deformable coupling portions
Data Source
AI summary
A bus bar module includes a plurality of bus bars and a bus bar holder. The bus bar holder is constituted by coupling a plurality of holding portions in a chain manner via deformable coupling portions, respectively, the plurality of holding portions each holding the bus bar in a movable manner in predetermined ranges determined by restriction of movement of the bus bar by interferences with movement restricting members. Openings allowing two contact portions of the bus bar held by the holding portion to be exposed to an outside, the two contact portions being respectively connected to the electrodes of the two adjacent battery cells, are provided in either the holding portion or the coupling portion.