Battery Module Hinge Assembly for Stable Bus-Bar Frame Coupling
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Solution Overview
Problem
Conventional battery modules face issues with the separation of bus-bar frames and upper plates during assembly or movement, leading to damage of flexible printed circuit boards and internal cell assemblies, necessitating a solution to prevent such separation and facilitate precise assembly.
Innovation Solution
A battery module design featuring a hinge pin and hinge coupling portion with a coupling protrusion and groove system, where the hinge pin is completely covered, allowing for snap-fit assembly and limiting pivoting of the bus-bar frame to prevent separation and ensure precise alignment with the upper plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bus-bar frame and upper plate are assembled conventionally, then the assembly process is simple, but the components may separate during movement or assembly causing damage to flexible printed circuit boards and internal cell assemblies
Solution Approach 1:
The hinge pin is received within the hinge coupling portion, creating a nested structure where the pin fits into a dedicated receptacle. This nesting provides secure mechanical interlocking while maintaining a compact design, preventing separation during movement without requiring overly complex external fastening mechanisms.
Solution Approach 2:
The hinge pin acts as an intermediary component that mediates the connection between the bus-bar frame and upper plate. By introducing this intermediate element with specific coupling features (protrusion and groove), the design achieves reliable connection stability while keeping the overall structure manageable and not excessively complex.
2Ease of operation
If the bus-bar frame is allowed to pivot freely during assembly, then ease of assembly is improved, but excessive pivoting causes damage to internal cell assemblies
Solution Approach 1:
The coupling protrusion and groove are designed to engage in a predetermined sequence during assembly. The preliminary positioning features guide the bus-bar frame into the correct orientation before final engagement, allowing easy initial placement while preventing excessive pivoting that could damage internal components. The structure inherently limits the range of motion to safe parameters.
3Ease of manufacture
If the hinge pin is exposed during assembly, then manufacturing is simpler, but the flexible printed circuit board may be torn during separation of bus-bar frame and upper plate
Solution Approach 1:
The hinge pin is nested within the hinge coupling portion, with the pin received inside a dedicated receptacle structure. This nested configuration provides inherent protection for the flexible printed circuit board by preventing direct exposure and contact with moving parts during assembly and operation, eliminating the tearing risk while maintaining manufacturing feasibility through standard nesting techniques.
Data Source
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AI summary
A battery module according to the present disclosure includes: a cell assembly that includes at least one battery cell; an upper plate that covers one side of the cell assembly, and includes a hinge pin at at least one corner thereof; and a bus-bar frame that covers the other side, which neighbors the side of the cell assembly, covered by the upper plate, and coupled to the upper plate by including a hinge coupling portion that is coupled with the hinge pin, wherein the hinge coupling portion comprises a hinge pin receiving portion where the hinge pin is received and a hinge pin cover portion that covers the hinge pin, and one of the hinge pin and the hinge coupling portion comprises a coupling protrusion portion, and the other comprises a coupling groove portion corresponding to the coupling protrusion portion.