Battery Module Assembly With Molded Bus Bar Frames and Swelling Clamps
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Solution Overview
Problem
The existing battery module assembly requires separate bus bars and cartridges for connecting battery cells in series and parallel, which increases complexity, cost, weight, and size, and is vulnerable to cell swelling due to inadequate surface pressure.
Innovation Solution
The battery module assembly integrates bus bars and cartridges into molded frames, eliminating the need for separate components and using clamps to maintain surface pressure, thereby reducing complexity, weight, and size while preventing cell swelling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate bus bars and cartridges are used to connect battery cells in series and parallel, then electrical connection functionality is achieved, but device complexity increases
Solution Approach 1:
The patent combines separate bus bars and cartridges into an integrated molded frame structure. The frame simultaneously serves as the structural support (cartridge function) and the electrical connection component (bus bar function), eliminating the need for separate components and reducing assembly complexity.
Solution Approach 2:
The molded frame is designed to perform multiple functions: it provides structural support for the battery cells, maintains spacing between cells, and incorporates integrated bus bars for electrical connections. This multi-functional design reduces the total number of components required in the battery assembly.
2Reliability
If separate bus bars and cartridges are used for battery cell connections, then electrical connectivity is ensured, but weight increases
Solution Approach 1:
By merging the cartridge and bus bar into a single molded frame component, the total material usage is reduced. The integrated structure eliminates redundant materials and fasteners that would be required for separate components, thereby reducing the overall weight of the battery module.
3Reliability
If separate bus bars and cartridges are used to connect battery cells, then electrical connections are established, but manufacturing cost increases
Solution Approach 1:
The integration of multiple components into a single molded frame reduces the number of parts that need to be manufactured, stored, and assembled. This consolidation simplifies the supply chain and manufacturing process, leading to cost reductions despite the increased complexity of the molding process itself.
Solution Approach 2:
The multi-functional molded frame eliminates the need for separate manufacturing processes for cartridges and bus bars, allowing for a single optimized manufacturing process. This reduces tooling costs, production time, and overall manufacturing complexity.
4Stability of the object's composition
If separate bus bars and cartridges are used for battery assembly, then structural support is provided, but assembly size increases
Solution Approach 1:
The molded frame integrates the structural support functions of the cartridge with the electrical connection functions of the bus bar into a single compact component. This integration eliminates the space required for separate components and their associated fasteners and mounting structures, reducing the overall assembly size.
5Ease of manufacture
If traditional battery module assembly is used without integrated clamps, then battery cells can be assembled, but cell swelling occurs due to insufficient surface pressure
Solution Approach 1:
The clamp is integrated into the molded frame structure, combining the structural support function with the pressure application function. This integration ensures that the clamp maintains constant surface pressure on the battery cells to prevent swelling while being part of the overall structural framework.
6Device complexity
If molded frames with integrated bus bars are used, then device complexity is reduced, but manufacturing process complexity increases
Solution Approach 1:
The molded frame is designed as a multi-functional component that integrates structural support, electrical connection, and cell pressure functions. While the molding process itself is complex, the resulting single-component design simplifies assembly and reduces the total number of parts, providing long-term manufacturing benefits.
Data Source
AI summary
A battery module assembly includes a front frame and a rear frame installed on the front and rear surfaces of the cell assembly and configured to mold a bus bar for electrically connecting battery cells included in the cell assembly, a left end plate and a right end plate respectively covering both side surfaces of the cell assembly, an upper clamp and a lower clamp disposed over an upper portion and a lower portion of the cell assembly, respectively clamping an upper portion and a lower portion of each of the left end plate and the right end plate, and pressing both side surfaces of the cell assembly disposed between the left end plate and the right end plate, and a front cover and a rear cover covering the front frame and the rear frame. A long hole formed in an upper portion and a lower portion of the front cover and the rear cover, and a pipe disposed on an inner perimeter surface of the long hole.