Battery Module Bus Bar Positioning Guide
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Solution Overview
Problem
In battery modules, maintaining the correct positions of bus bars during welding is challenging, leading to inefficiencies in the electrical connection and output performance of secondary batteries.
Innovation Solution
A position arrangement unit with guide portions on the terminal plates helps maintain the correct positioning of bus bars, ensuring accurate assembly and improved welding efficiency by preventing deviations and providing defined welding positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If bus bars are welded to terminal plates without position arrangement, then welding process is simpler, but welding precision and position accuracy deteriorate
Solution Approach 1:
The guide portion acts as an intermediary element between the terminal plate and the bus bar. It provides a physical reference structure that mediates the positioning process, ensuring accurate alignment without requiring complex external fixtures or measurement systems during welding.
Solution Approach 2:
The guide portion is pre-formed as an integral part of the terminal plate structure before the welding process begins. This preliminary positioning structure is already in place to guide the bus bar into the correct position, eliminating the need for complex real-time adjustment mechanisms during assembly.
2Productivity
If bus bars are positioned without guide portions, then assembly process is faster, but welding efficiency and connection reliability deteriorate
Solution Approach 1:
The guide portion serves as a positioning intermediary that ensures reliable electrical connection by maintaining precise bus bar placement. This simple structural feature provides consistent positioning without requiring complex measurement or adjustment procedures, thereby maintaining both speed and reliability.
3Manufacturing precision
If bus bar position is not regulated, then manufacturing process is simpler, but output performance and electrical connection quality deteriorate
Solution Approach 1:
The guide portion is incorporated into the terminal plate design as a pre-formed feature that automatically provides positioning guidance. This preliminary structural element simplifies the manufacturing process by eliminating the need for separate positioning fixtures or complex alignment procedures during assembly.
Solution Approach 2:
The guide portion acts as a built-in intermediary structure that translates the terminal plate geometry into precise bus bar positioning. This intermediary feature maintains manufacturing simplicity while achieving high connection precision through its geometric design rather than complex mechanisms.
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
This solution enhances the welding efficiency and stability of bus bars, resulting in improved electrical connections and enhanced performance of battery modules by maintaining precise positions during the welding process.
Implementation Method 1
a bus bar connecting the electrode terminal of a first battery unit of the plurality of battery units and the electrode terminal of a second battery unit of the plurality of battery units
Implementation Method 2
the bus bar is welded to the first and second terminal plates
Data Source
AI summary
A battery module includes a plurality of battery units, each including an electrode assembly and an electrode terminal electrically connected to the electrode assembly; a bus bar connecting the electrode terminal of a first battery unit of the plurality of battery units and the electrode terminal of a second battery unit of the plurality of battery units; and a position arrangement unit configured to maintain a position of the bus bar relative to the electrode terminals of the first and second battery units.