Battery Module Terminal Structure With Floating Nut Alignment
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Solution Overview
Problem
The assembly of battery modules with a bolt and nut structure is hindered by the need for precise position control, leading to increased defect rates and component costs due to the requirement for precise alignment and additional processes like bonding and welding.
Innovation Solution
A terminal connecting structure is developed where a nut can float within a nut insertion chamber, allowing for improved ease of assembly and reduced precision requirements, with a bolt penetrating through a fastening hole and screw-coupling to the nut, eliminating the need for precise alignment and additional constraining processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a bolt and nut fastening structure is applied to connect battery modules, then the connection strength is improved, but the assembling properties deteriorate due to the need for precise position control
Solution Approach 1:
The nut is designed to float within a nut insertion chamber rather than being fixed in position. This dynamic configuration allows the nut to move and self-align with the bolt during assembly, eliminating the need for precise position control while maintaining connection strength.
Solution Approach 2:
The nut insertion chamber acts as an intermediary structure that accommodates the floating nut. This chamber provides the space and freedom of movement needed for the nut to self-align with the bolt, facilitating easier assembly while preserving the fastening function.
2Strength
If a bolt and nut fastening structure is applied to connect battery modules, then the connection strength is improved, but the defect rate increases due to the requirement for precise alignment
Solution Approach 1:
The floating nut configuration allows the nut to dynamically adjust its position during assembly, compensating for alignment variations. This reduces assembly errors and defects while maintaining the required connection strength between battery modules.
Solution Approach 2:
The nut insertion chamber is designed beforehand to accommodate the floating nut's movement range. This pre-planned space cushioning allows the nut to self-align and absorb positioning tolerances, preventing assembly defects before they occur.
3Manufacturing precision
If additional processes such as bonding and welding are applied to constrain the nut to the battery module, then the nut positioning is improved, but the component prices increase
Solution Approach 1:
Instead of using additional bonding or welding processes to fix the nut position, the design employs a floating nut within an insertion chamber. This dynamic approach achieves adequate positioning through the nut's ability to self-align during assembly, eliminating complex and costly additional processes.
Solution Approach 2:
The invention extracts and eliminates the need for additional constraining processes (bonding, welding) by using the floating nut mechanism. The nut insertion chamber provides the necessary positioning function without requiring extra manufacturing steps, thereby reducing component costs.
4Measurement precision
If precise position control is applied to assemble the bolt to the nut, then the assembling accuracy is improved, but the assembly speed decreases
Solution Approach 1:
The floating nut configuration enables the nut to automatically align with the bolt during the assembly process. This dynamic self-alignment eliminates the need for precise position control operations, thereby maintaining assembling accuracy while significantly improving assembly speed.
Solution Approach 2:
The floating nut performs self-alignment and self-positioning during assembly through its movement within the insertion chamber. This self-service mechanism achieves the necessary assembling accuracy without requiring external position control operations, thus enhancing assembly speed.
Data Source
AI summary
A battery module of the present disclosure may include, a cell assembly including at least one battery cell, a busbar assembly including a terminal busbar electrically connected to an electrode lead of the cell assembly, and a busbar frame covering the cell assembly on at least one side, and an insulating frame covering the busbar assembly from the outside, and further including a nut which is set to a floatable size in a nut insertion chamber adjacent to a terminal busbar and provided with a space inside the insulating frame, and is mounted in the nut insertion chamber.