Battery Module Busbar Alignment Using Pressure Pad Compression
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Solution Overview
Problem
The challenge of maintaining the positional accuracy of terminal busbars and restricting the movement of cell blocks within battery modules is not adequately addressed in current battery technologies, leading to potential misalignment and assembly difficulties.
Innovation Solution
A battery module design incorporating a busbar frame with protrusions, insulating covers, and compressible foam pads that pressurize the cell stack, ensuring precise alignment of terminal busbars through the use of pressure pads and fixing members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple battery cells are connected in series/parallel to form a battery module, then the charge/discharge capacity and output voltage are improved, but the cell block may move within the clearance between the cell block and module frame, causing positional inaccuracy of terminal busbars
Solution Approach 1:
The patent employs insulating covers made of flexible material that can elastically deform to accommodate the cell block while maintaining positional constraint. The insulating cover acts as a flexible shell that absorbs movement and maintains the positional relationship between the cell block and terminal busbar, resolving the contradiction between accommodating multiple cells and maintaining positioning accuracy.
Solution Approach 2:
The patent introduces a pressure pad that applies pre-compression force to the cell block through the insulating cover, creating a cushioning effect that prevents movement before it occurs. This beforehand cushioning ensures the cell block remains firmly positioned within the module, maintaining manufacturing precision while allowing for thermal expansion and contraction during operation.
2Ease of manufacture
If the cell block is allowed to move freely within the module frame clearance, then the assembly process is simplified, but the terminal busbar hole position accuracy deteriorates
Solution Approach 1:
The insulating cover with integrated pressure pad creates a self-positioning system that automatically constrains the cell block to the correct position during assembly. The flexible material and pre-compression design allow the system to self-adjust and maintain positional accuracy without requiring complex external fixtures or adjustment mechanisms, thus maintaining ease of manufacture while improving precision.
3Manufacturing precision
If rigid fixing structures are used to prevent cell block movement, then position accuracy is improved, but the device complexity and difficulty of assembly increase
Solution Approach 1:
The patent replaces complex rigid fixing structures with a simple flexible insulating cover that inherently provides positioning through its elastic deformation characteristics. This flexible shell approach maintains position stability while significantly reducing structural complexity and assembly difficulty compared to rigid mechanical fixtures.
Solution Approach 2:
The patent utilizes the elastic modulus and compression characteristics of the insulating cover material to achieve positioning without complex mechanical structures. By changing the physical parameters of the fixing mechanism (from rigid to elastic), the system achieves both position stability and simplicity, avoiding the need for multiple fasteners, adjustment mechanisms, or complex geometric constraints.
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 effectively restricts the position of cell blocks and enhances the accuracy of terminal busbar hole positioning, improving assembly efficiency and reducing misalignment issues.
Implementation Method 1
the pressure pad of the one insulating cover pressurizes the battery cell stack in a direction of the other insulating cover disposed on the outside of the busbar frame
Implementation Method 2
the pressure pad may be a foam pad
Data Source
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AI summary
A battery module according to an embodiment of the present disclosure includes a battery cell stack in which a plurality of battery cells is stacked, a module case for accommodating the battery cell stack, a busbar frame disposed on one side of the battery cell stack, and two insulating covers disposed on both sides of the battery cell stack, wherein one of the two insulating covers includes a pressure pad, the other insulating cover is disposed on the outside of the busbar frame, and the pressure pad of the one insulating cover pressurizes the battery cell stack in a direction of the other insulating cover disposed on the outside of the busbar frame.