Battery Module Bus Bar Holder with Elastic Side Plate Gaps
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Solution Overview
Problem
Rechargeable battery modules are vulnerable to mechanical impact due to inadequate fastening forces between the side plates, bus bar holder, and unit cells, which can lead to structural instability and damage.
Innovation Solution
The rechargeable battery module incorporates a bus bar holder made of synthetic resin with protruded brackets and a side plate with elastic connecting portions, forming gaps to absorb welding heat and provide strong fastening forces in multiple directions, combined with a buffer member to enhance mechanical impact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the side plate and bus bar holder are rigidly connected without gaps, then the fastening force is maximized, but welding heat causes deformation and structural damage
Solution Approach 1:
The patent incorporates gaps between the side plate and bus bar holder brackets before welding to absorb welding heat and prevent deformation. These gaps act as预先 prepared cushioning spaces that accommodate thermal expansion and heat distribution during the welding process, thereby maintaining structural integrity while achieving strong fastening forces.
2Device complexity
If the battery module structure is simplified without multiple connection components, then the device complexity is reduced, but the resistance to mechanical impact deteriorates
Solution Approach 1:
The patent divides the connection structure into multiple functional segments: the side plate with connecting portions, the bus bar holder with brackets, and the gaps between them. This segmentation allows each component to perform its specific function - the side plate provides structural support, the brackets provide attachment points, and the gaps provide thermal management - thereby achieving high mechanical impact resistance through a relatively simple overall structure.
3Object-affected harmful factors
If the connecting portions are made elastic to absorb impact, then the mechanical impact resistance is improved, but the manufacturing precision becomes more difficult to control
Solution Approach 1:
The patent utilizes the elastic properties of the connecting portions by changing the material parameters and geometric parameters of these components. The connecting portions are designed with specific elastic moduli and geometric configurations that allow them to deform elastically under mechanical impact while maintaining manufacturability. This parameter optimization enables the structure to absorb impact energy without requiring extremely precise manufacturing tolerances.
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 enhanced fastening forces and structural design effectively protect the battery module from mechanical impacts in the y-axis and z-axis directions, improving its durability and stability.
Implementation Method 1
The connecting portion may include an elastic portion bent at a lower side of the connecting portion to have an elastic force toward the bracket
Implementation Method 2
The bus bar holder may be provided with a buffer member to be interposed between the coupling inducement groove and the unit cell
Data Source
AI summary
A rechargeable battery module is disclosed. In one aspect, the battery module includes a plurality of unit cells including first and second outermost unit cells disposed at first and second opposing ends of the unit cells arranged in a first direction, wherein the unit cells have top and bottom surfaces opposing each other. The battery module also includes a bus bar holder covering the top surface of the unit cells, a bus bar disposed at the bus bar holder to electrically connect the unit cells and a pair of end plates respectively supporting the first and second outermost unit cells. The battery module further includes a pair of side plates disposed at third and fourth opposing ends of the unit cells arranged in a second direction crossing the first direction, wherein the side plates are connected to the end plates and the bus bar holder.