Battery Module Hinge Structure to Prevent Bus Bar Frame Separation
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Solution Overview
Problem
Conventional battery module designs face issues with the separation of the bus bar frame and cover plate, leading to potential damage of the flexible printed circuit board and difficulties in assembly.
Innovation Solution
A rotatable bus bar frame connected to a cover plate via a unique connecting part with a bar-shaped fixing part and groove parts, featuring an inclined surface and hooking surface for secure engagement, along with a separation-preventing wall to maintain assembly stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a hinge structure is formed by connecting a U-shaped hook type and a bar-shaped structure, then the bus bar frame and cover plate can be assembled, but the assembled part may separate during the process or during movement, causing damage to the flexible printed circuit board
Solution Approach 1:
The bus bar frame is designed to be rotatable relative to the cover plate, allowing dynamic adjustment during assembly and operation. This rotational capability enables the structure to accommodate movement without separation while maintaining secure connection through the inclined surface engagement mechanism
Solution Approach 2:
The inclined surface on the fixing part预先 (in advance) prevents separation by creating a mechanical interlock that resists outward forces. The wedge-shaped geometry of the inclined surface generates opposing forces that counteract any separation tendency before it can cause damage to the flexible printed circuit board
2Reliability
If the bus bar frame and cover plate are securely connected to prevent separation, then reliability is improved, but the assembly process becomes more complex
Solution Approach 1:
The connecting part is divided into distinct functional elements: the fixing part with the inclined surface and the accommodating part with the groove part. This segmentation allows each element to perform its specific function independently while simplifying the overall assembly process through modular integration
Solution Approach 2:
Instead of using a complex locking mechanism to prevent separation, the design inverts the approach by using a simple inclined surface that naturally guides the fixing part into the accommodating part during assembly. The separation prevention is achieved through the geometric constraint of the inclined surface engagement rather than additional fastening elements
Data Source
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AI summary
A battery module includes: a cell assembly including at least one battery cell; a cover plate covering a first surface of the cell assembly; and a bus bar frame covering a second surface adjacent to the first surface of the cell assembly and connected to the cover plate so as to be rotatable. The cover plate and the bus bar frame are connected by at least one connecting part including a fixing part and a pair of accommodating parts. The fixing part protrudes from a corner of the bus bar frame and is formed of a bar shape parallel to the corner. The pair of accommodating parts protrudes from the cover plate and includes a groove part into which two opposing end parts of the fixing part are inserted. The fixing part includes an inclined surface so that the width of the fixing part decreases toward both opposing end parts.