Stacked Bus Bar Terminal Structure for Safer Battery Module Rows
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Solution Overview
Problem
Conventional battery pack designs for electric vehicles face issues with thermal runaway leading to accelerated fire and explosion due to heat transfer between adjacent battery modules, and they have unused space that reduces energy density.
Innovation Solution
A terminal connection structure where bus bar modules are stacked vertically between rows of battery modules, using insulated terminal blocks and fastening bolts to electrically connect positive and negative terminals, and employing a copper bolt for secure connection, thereby reducing the risk of fire and increasing energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bus bars are arranged horizontally to face each other between rows of battery modules, then electrical connection between battery modules is achieved, but heat transfer between adjacent electrodes occurs causing thermal runaway and fire risk
Solution Approach 1:
The patent changes the arrangement dimension of bus bars from horizontal (facing each other between rows) to vertical (stacked above and below battery modules). This dimensional change eliminates direct horizontal proximity between positive and negative terminals of adjacent modules, thereby preventing heat transfer-induced thermal runaway while maintaining electrical connectivity.
Solution Approach 2:
The patent introduces terminal blocks as intermediary components that accommodate and organize bus bars. These terminal blocks serve as mediators between battery modules and bus bars, providing structured connection points that enable vertical stacking arrangement and isolate adjacent electrodes from direct thermal contact.
2Quantity of substance
If bus bars are arranged horizontally between rows of battery modules, then electrical connection is established, but unused space above bus bars reduces energy density of the battery pack
Solution Approach 1:
The patent transitions from horizontal bus bar arrangement to vertical stacking arrangement. This repositioning eliminates the unused space above horizontally-oriented bus bars by utilizing the vertical dimension, thereby maximizing space utilization and improving energy density without compromising electrical connection functionality.
Solution Approach 2:
The patent merges the functions of electrical connection and space utilization by implementing vertical stacking of bus bar modules. This combination eliminates wasted space while maintaining all necessary electrical connections, effectively converting previously unused volume into productive space within the battery pack.
Data Source
AI summary
A terminal connection structure of a battery is disclosed. A terminal connection structure of the battery is for electrically connecting positive and negative terminals of battery modules of a first row and battery modules of a second row that is adjacent to the first row in a plurality of rows where battery modules are arranged. The terminal connection structure of the battery may include: a first bus bar module electrically connecting the positive and negative terminals in the first row of battery modules; and a second bus bar module configured to electrically connected to the positive and negative terminals in the battery modules of the second row, stacked vertically on the first bus bar module, to be electrically connected to the first bus bar module.