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Used to provide structural support to the vertical mounting points of busbars. See figure below [3]. Mounted using embedded captive nuts and isolated bolts, isolated using insulating washers(now acting as the isolation covers(rev 2)) [4].
Extra clearance was added for the screws that are covered by the gusset plates to ensure that the gusset plates would be able to sit flat against the surface.[6]
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Insulation Covers:
Covers used to insulate screws on busbar connections on revision 0 of battery modules [3]. See Gusset Plates.
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Non-conductive parts used to aid in mounting and busbar connections. Battery cells were accommodated via the use of circular holes in the cell holders. Cell holders also included other mounting features for gusset plates, isolation plates, etc. [3].
Aluminum standoffs(completely isolated from busbars & electrical parts) were added at 4 points central to the module to provide a secondary mechanism to keep the modules together (other than friction). These aluminum standoffs will also be covered with heat shrink to further reduce chances of shorting with damaged modules.[4]
Isolation Plates:
A plate covering the entire horizontal surface of busbars on top of modules to isolate busbars [3]. This is made up of 2 layers: fish paper (electrical grade vulcanized fiber with adhesive backing) [4], and some sort of rigid material used in rev 2+. The fish paper is applied directly to the busbars immediately after spot welding to avoid potential short circuits when manufacturing [4]. Better materials, e.g. Formex were proposed, however, it is noted that these materials may be difficult to find or costly to obtain. The final module used potting compound instead of fish paper to fully encapsulate the spot welds [7]. See Potting Batteries .
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Both positive and negative terminals were at the rear of the pack which allows for easier mounting of HV components and eliminates unnecessary long wiring runs [3].
Joint resistance calculations:
Electrical Contact Resistance for Module to Module Series Connections
Module Mounting:
The modules will still be mounted with discs glued to the bottom of the enclosure at the corners of the modules. [4]
They should also be the mounting points for cable management brackets in the outer rows[4]
Poron (polyurethane) added to bottom of modules to provide cushioning and vibration dampening[4]
Useful Terms:
Contact Resistance: Resistance added because of the interface between two surfaces. Useful to know because this occurs in the contact between anything that touches the busbars (Better check on that). It’s essential to minimize this to minimize power loss [3].
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