Battery CCS Structure for Precise Cell Alignment and Bus Bar Stability
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Solution Overview
Problem
The existing battery module structures face issues with poor positioning between support plates and cells, leading to unstable connections and a risk of short circuits, which poses safety hazards due to misalignment and excursion of bus bars.
Innovation Solution
A Cell Contact System (CCS) is designed with positioning protrusions on a fixing frame that align with cells, embedded bus bars for secure electrical connections, and heat-conductive adhesive for enhanced stability and safety, along with a bracket system for precise cell placement and structural adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a support plate and bus bar structure is used in the battery module, then electrical connection between cells is achieved, but positioning between the support plate and cells is poor leading to misalignment and connection instability
Solution Approach 1:
The support plate is segmented into multiple independent support components, each with its own positioning protrusions that fit into corresponding positioning grooves on the cells. This segmentation allows each component to be independently positioned and secured, improving overall positioning accuracy and connection stability while maintaining electrical connectivity.
Solution Approach 2:
Positioning protrusions and positioning grooves are introduced as intermediary structures between the support plate and cells. These intermediaries provide precise mechanical alignment and positioning, ensuring that the bus bar correctly aligns with the electrical terminals of the cells, thereby improving both positioning accuracy and connection stability.
2Ease of manufacture
If the bus bar is not securely positioned, then installation is simpler, but the bus bar may excursion leading to short circuit risks
Solution Approach 1:
Positioning grooves are pre-formed on the cell surfaces, and positioning protrusions are pre-formed on the support components. During assembly, these pre-formed features automatically guide and secure the bus bar in the correct position, preventing excursion before installation is complete. This preliminary preparation ensures safety without complicating the installation process.
Solution Approach 2:
The positioning protrusions and grooves create a self-aligning and self-securing mechanism. When the support plate is installed, the protrusions automatically engage with the grooves, securing the bus bar in place without requiring additional fastening operations. This self-service mechanism prevents short circuit risks while maintaining installation simplicity.
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 CCS effectively prevents short circuits by ensuring accurate cell alignment and stable connections, improving assembly efficiency and safety by limiting cell movement and distributing heat, while the bracket system ensures secure cell placement and insulation.
Implementation Method 1
heat-conductive adhesive for enhanced stability and safety, and can bond the fixing frame and the bus bar
Data Source
AI summary
Disclosed are a CCS, a battery module structure and a battery. The CCS is arranged at the tops of a plurality of cells, and a gap is formed between adjacent cells. The CCS includes a fixing frame and a bus bar. The fixing frame is arranged at the tops of the cells, and is provided with a plurality of positioning protrusions, the positioning protrusion can extend into the gap between adjacent cells and makes contact with the side faces of the cells, and the fixing frame is also provided with installation holes. The bus bar is embedded in the installation holes, makes contact with the cells and electrically connects the plurality of cells.