Battery Module Side Plate and Busbar Holder Integrated Assembly
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Solution Overview
Problem
The assembly process of battery modules is complicated due to the misalignment of side plates and busbar holders, which can lead to inefficiencies in space utilization and increased complexity.
Innovation Solution
A battery module design where the busbar holder and side plate are integrated on the same side of the battery cell, allowing for a more streamlined assembly process and improved space efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the side plate and busbar holder are disposed in different positions, then the assembly process becomes complicated, but maintaining separate positions allows for independent optimization of each component
Solution Approach 1:
The busbar holder is integrated with the side plate to form a unified structure. The side plate includes a receiving space that accommodates the busbar holder, allowing both components to be disposed together on the same side of the battery cell. This merging eliminates the complexity of coordinating separate positions while maintaining the functional independence of each component.
2Area of stationary object
If the busbar holder and side plate are disposed in different positions, then each component can be optimized independently, but the space utilization becomes inefficient
Solution Approach 1:
The busbar holder is nested within the receiving space of the side plate, forming a compact integrated structure. This nesting arrangement maximizes space utilization by eliminating gaps between separately positioned components, while the modular design allows each component to be manufactured and optimized independently before assembly.
3Productivity
If the busbar holder is integrated with the side plate, then assembly is simplified and space efficiency is improved, but the structural design becomes more complex
Solution Approach 1:
The integrated structure is segmented into distinct functional zones: the side plate with its receiving space, the busbar holder with its support and seating portions, and the busbar. This segmentation allows for standardized manufacturing of each segment while achieving simplified assembly through their integrated configuration, reducing overall structural design complexity.
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 design simplifies the assembly process and enhances space efficiency by integrating the busbar holder and side plate, reducing complexity and improving performance.
Implementation Method 1
The busbar and the cell terminal may be melt-joined by welding.
Implementation Method 2
The busbar and the cell terminal may be laser-welded through the first opening portion and the second opening portion.
Data Source
AI summary
A battery module includes a battery cell, a side plate facing a side of the battery cell and including a first opening portion, a cell terminal protruding from the battery cell toward the side plate, a busbar holder coupled to the side plate, located between the side plate and the battery cell, and including a second opening portion in communication with the first opening portion, and a busbar supported by the busbar holder, covering the second opening portion, and connected to the cell terminal.