Battery Module Assembly With Integrated Bus Bar Terminals
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Solution Overview
Problem
The existing battery module assembly process is time-consuming due to the separate manufacturing and assembly of bus bars, which increases the complexity and duration of the manufacturing process.
Innovation Solution
Incorporating a bus bar directly into the battery module design, where the first input/output terminal extends from the module case and includes a recess portion to connect with adjacent modules, reducing the need for separate bus bars and simplifying the assembly by allowing modules to be connected internally.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate bus bar is manufactured and assembled to the battery module using bolts and nuts, then reliable electrical connection between battery modules is achieved, but the assembly process time increases and manufacturing complexity increases
Solution Approach 1:
The bus bar is merged with the battery module structure by extending the module bus bar outward to form an integrated input/output terminal. This eliminates the separate bus bar component and its associated fastening hardware (bolts, nuts), directly reducing assembly steps and time while maintaining reliable electrical connection between modules.
2Reliability
If a separate bus bar is manufactured and assembled to the battery module using bolts and nuts, then reliable electrical connection between battery modules is achieved, but the device complexity increases
Solution Approach 1:
The bus bar function is merged into the battery module's existing bus bar structure. The module bus bar is extended outward to serve as the input/output terminal, eliminating the need for separate bus bar components and their associated fastening hardware (bolts, nuts), thereby reducing structural complexity.
Solution Approach 2:
The module bus bar serves dual functions: it connects battery cells within the module and extends outward to serve as the input/output terminal for inter-module connections. This multi-functionality eliminates the need for separate dedicated bus bar components.
Data Source
AI summary
An embodiment of the invention provides a battery module assembly, including: a first battery module including a first module case housing a plurality of battery cells, and a first input/output terminal and a second input/output terminal that are provided at one side of the first module case; and a second battery module including a second module case housing a plurality of battery cells, and a first input/output terminal and a second input/output terminal that are provided at one side of the second module case. The first input/output terminal of the first battery module may be formed by extending a first module bus bar connected to at least one of the plurality of battery cells inside the module case, and may extend to the second input/output terminal of the second battery module to be connected to the second input/output terminal.