Battery Module Fuse Bar Fixing for Faster Busbar Assembly
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Solution Overview
Problem
The existing battery modules lack a fixing unit for the fuse bar, leading to increased time and cost in securing the fuse bar to the busbar holder, thereby decreasing the overall process efficiency.
Innovation Solution
A battery module with a fixing unit that secures the fuse bar to the busbar holder, including a fuse bar connected to adjacent cell rows to block overcurrents and a fixing unit that stabilizes the fuse bar's position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an additional fixing unit is separately manufactured and installed to fix the fuse bar, then the fuse bar can be securely attached to the busbar holder, but the time and cost of assembly increase and process efficiency decreases
Solution Approach 1:
The fixing unit is integrated into the busbar holder as a unified structure. The busbar holder includes fixing protrusions that directly engage with the fuse bar, eliminating the need for separate fixing components. This merging of functions allows the busbar holder to simultaneously support busbars and secure the fuse bar through its built-in fixing protrusions, thereby reducing assembly steps and improving process efficiency while maintaining reliable attachment.
2Reliability
If an additional fixing unit is separately manufactured and installed to fix the fuse bar, then the fuse bar can be securely attached to the busbar holder, but the manufacturing cost increases
Solution Approach 1:
The fixing unit is integrated into the busbar holder as a unified structure. The busbar holder includes fixing protrusions that directly engage with the fuse bar, eliminating the need for separate fixing components. This merging of functions allows the busbar holder to simultaneously support busbars and secure the fuse bar through its built-in fixing protrusions, thereby reducing assembly steps and improving process efficiency while maintaining reliable attachment.
Solution Approach 2:
The busbar holder is designed to perform multiple functions: supporting busbars, securing the fuse bar through integrated fixing protrusions, and providing structural framework. This multi-functionality reduces the total number of components needed, simplifying manufacturing and reducing costs while ensuring reliable fixation of the fuse bar.
Data Source
AI summary
A battery module includes a battery array including two or more cell rows in each of which unit cells are arranged along a first direction, the two or more cell rows being arranged along a second direction perpendicular to the first direction; and a busbar assembly including busbars connecting unit cells in each of the two or more cell rows and a busbar holder that fixes the busbars. Further, the battery module includes a fuse bar disposed onto the busbar holder at a boundary region of the two or more cell rows to electrically connect row connecting cells that are unit cells of adjacent cell rows in the second direction, and to block an overcurrent exceeding a set value from being drawn to the adjacent cell row, and a fixing unit that fixes the fuse bar to the busbar holder at the boundary region.