Battery Module Holder Aligning Bus Bar
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing battery module manufacturing process is inefficient due to difficulties in correctly aligning bus bars with rechargeable battery terminals, leading to potential electrical contact failures and performance deterioration under external impacts or vibrations.
Innovation Solution
A battery module design featuring a holder with specific fastening and supporting structures that securely position and bond the bus bar to the terminals, preventing misalignment and contact failures through the use of protrusions, grooves, and a protecting member with adhesive tape, ensuring stable electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a jig is used to locate the bus bar at a correct position, then the bus bar alignment precision is improved, but the device complexity and manufacturing time increase
Solution Approach 1:
The holder is designed with pre-formed supporting protrusions and grooves that automatically guide the bus bar into the correct position during assembly. This preliminary structural preparation eliminates the need for complex jigs and locating devices, as the alignment function is built into the holder itself.
Solution Approach 2:
The alignment function is extracted from the separate jig tooling and integrated directly into the holder structure. The supporting protrusions and grooves on the holder perform the locating function that previously required external jigs, simplifying the overall manufacturing process.
2Manufacturing precision
If a jig is used to locate the bus bar, then the alignment accuracy is improved, but the manufacturing time increases
Solution Approach 1:
The holder incorporates pre-formed supporting protrusions and grooves that automatically guide the bus bar into the correct position during assembly. This preliminary structural preparation eliminates the need for complex jigs and locating devices, as the alignment function is built into the holder itself.
3Reliability
If the bus bar is bonded to the terminal, then the electrical connection is established, but the contact reliability decreases under external impacts or vibrations
Solution Approach 1:
The holder merges multiple functions into a single structure: it provides mechanical support for the battery pack, incorporates alignment features (supporting protrusions and grooves) for the bus bar, and provides bonding surfaces for securing the bus bar. This integrated structure ensures the bus bar maintains correct position and reliable electrical connection under external impacts and vibrations.
4Reliability
If the bus bar is securely positioned using fastening structures, then the contact failure is prevented, but the device complexity increases
Solution Approach 1:
The holder merges multiple functions into a single structure: it provides mechanical support for the battery pack, incorporates alignment features (supporting protrusions and grooves) for the bus bar, and provides bonding surfaces for securing the bus bar. This integrated structure ensures the bus bar maintains correct position and reliable electrical connection under external impacts and vibrations.
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 solution allows for easy and accurate alignment of the bus bar, preventing contact failures and enhancing the durability and performance of the battery module by stabilizing the bus bar position and reducing the impact of external vibrations.
Implementation Method 1
the protecting member may be provided with tape attached to the bus bar
Data Source
AI summary
A battery module according to an exemplary embodiment of the present invention includes a plurality of rechargeable batteries having a terminal, a holder combined to end portions of the rechargeable batteries and having a first fastening portion, and a bus bar combined to the terminal, electrically connecting the rechargeable batteries, and having a second fastening portion to be fitted into the first fastening portion.