Battery Module Bus Bar Frame Alignment to Prevent Bending
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The bending of bus bar frames in battery modules, particularly in large-area modules, leads to assembly and manufacturing defects due to increased size and pressure on electrode leads, making stable mounting of components difficult.
Innovation Solution
A battery module design featuring protrusions on the bus bar frame and insertion holes in the module frame, which prevent bending by aligning and securing the bus bar frame in the protruding direction of electrode leads, enhancing assembly and manufacturing processability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the bus bar frame size is increased to accommodate larger battery modules, then the battery module capacity and output are improved, but the bus bar frame becomes bent and assembly difficulty increases
Solution Approach 1:
The invention adds a new dimensional feature (protrusions extending in the third dimension) to the bus bar frame structure. These protrusions engage with corresponding recesses in the battery cell stack, creating a multi-point support system that prevents bending in the x-axis direction while maintaining the large frame size needed for high power output
Solution Approach 2:
The protrusions are pre-formed on the bus bar frame before assembly, and the corresponding recesses are pre-formed on the battery cell stack. This preliminary preparation ensures that when assembled, the bus bar frame is immediately supported at multiple points, preventing bending before any operational stresses are applied
2Quantity of substance
If the bus bar frame size is increased, then battery capacity is improved, but assembly processability deteriorates
Solution Approach 1:
The protrusions add vertical dimensionality to the assembly interface, creating automatic alignment features that guide the bus bar frame into correct position during assembly. This eliminates the need for complex alignment procedures while accommodating larger battery capacities
Solution Approach 2:
The protrusion-recess structure enables self-alignment and self-positioning during assembly. The geometry of the protrusions and recesses automatically guides correct placement, reducing the skill level and time required for assembly operations on large-capacity battery modules
3Power
If the bus bar frame is made larger, then battery output is improved, but component mounting stability deteriorates
Solution Approach 1:
The protrusions create additional vertical engagement points between the bus bar frame and battery cell stack. This multi-level engagement provides superior mechanical stability for mounting bus bars and connectors, preventing the frame from shifting or deforming under operational loads in high-power applications
Solution Approach 2:
The support function is segmented into multiple discrete protrusion points rather than relying on continuous frame contact. This segmentation distributes mechanical loads across multiple localized support points, enhancing the stability of mounted components throughout the large bus bar frame structure
Data Source
AI summary
A battery module includes a battery cell stack, a module frame, and a bus bar frame. The battery cell stack is configured to include a plurality of battery cells including electrode leads that are stacked in in the battery cells. The module frame is configured to accommodate the battery cell stack. The bus bar frame is positioned in a protrusion direction of the electrode leads protruding from the battery cells. A protrusion is formed in either the bus bar frame or the module frame. An insertion hole into which the protrusion is inserted is formed in the other of the bus bar frame and the module frame than the one of the bus bar frame and the module frame in which the protrusion is formed.