Battery Module Bus Bar Cover Integration for Precise Lead Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The assembly of battery modules is hindered by issues such as bus bar frame deviation, hinge structure damage, and alignment difficulties between electrode leads and bus bars, leading to manufacturing challenges and reduced precision.
Innovation Solution
A battery module design featuring an integrally formed bus bar frame and upper cover, with slits for electrode lead insertion, simplifying the assembly process and ensuring precise electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a bus bar frame with hinge structure is used to connect the upper assembly and bus bar, then the battery module can be assembled, but the bus bar frame deviates and flows in the hinge part, and the flexible printed circuit board is damaged
Solution Approach 1:
The patent merges the upper assembly and bus bar frame into a single integrated structure, eliminating the hinge connection that caused deviation and damage. The upper assembly now includes both the upper cover and bus bar frame as one piece, preventing the structural instability and component damage associated with separate hinge connections.
2Ease of manufacture
If the bus bar frame is rotated and combined with the electrode lead, then electrical connection is achieved, but it is difficult to align the electrode lead and bus bar
Solution Approach 1:
The patent incorporates the bus bar frame directly into the upper assembly before final assembly, establishing predetermined alignment positions for the electrode leads. The upper assembly is designed with pre-positioned bus bar frames that automatically align with electrode leads during assembly, eliminating the need for difficult rotational alignment operations.
3Adaptability or versatility
If the upper assembly and bus bar frame are connected by hinge, then the structure can be assembled, but the hinge part causes component damage and assembly complexity
Solution Approach 1:
The patent eliminates the hinge connection by merging the upper assembly and bus bar frame into a single integrated component. This integration removes the complex hinge mechanism entirely, simplifying the overall structure while maintaining the necessary functional relationships between components.
Data Source
AI summary
A battery module includes: a battery cell assembly including a plurality of battery cells adjacent to each other and stacked in parallel and a plurality of electrode leads protruded from respective ones of the plurality of battery cells; and a module cover accommodating the battery cell assembly, wherein the module cover includes an upper cover part exposing the plurality of electrode leads while covering an upper surface and a side surface of the battery cell assembly and a bus bar frame part coupled with the upper cover part and integrally formed with the upper cover part at a position corresponding to the plurality of electrode leads exposed by the upper cover part, and wherein the bus bar frame part includes a plurality of bus bars electrically connected to respective ones of the plurality of electrode leads.