Battery Module Terminal Cover Structure for Nut Fixation and Debris Blocking
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Solution Overview
Problem
Existing battery module structures face challenges in stabilizing the nut fixation during strong bolt tightening, limiting bolt rotation and allowing foreign matter entry due to friction, which can lead to contact failures and electrical issues.
Innovation Solution
A battery module design featuring a frame cover with a nut accommodation portion and a bolt accommodation groove, along with a reinforcing frame, to stabilize nut fixation and prevent foreign matter entry by ensuring sufficient bolt rotation and enhancing the fastening force, while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bolt is tightened with very strong force to prevent contact failure, then the coupling force between external terminal and module terminal is improved, but the structure surrounding the nut may not provide sufficient rigidity to stabilize the nut during strong tightening
Solution Approach 1:
The frame cover is segmented into distinct functional portions: a nut accommodation portion that stabilizes the terminal nut, a bolt accommodation portion that provides rotation space, and a barrier portion that isolates the fastening area. This segmentation allows each portion to optimize its specific function while working together to solve the overall contradiction.
Solution Approach 2:
The frame cover acts as an intermediary structure between the terminal nut and the external environment. It provides the barrier portion that prevents foreign matter (generated during bolt tightening) from entering the battery module interior, while simultaneously providing the rigidity needed to stabilize the nut during strong tightening operations.
2Reliability
If the bolt is strongly fastened to achieve high coupling force, then the fastening reliability is improved, but foreign matter generated by friction between bolt and nut may enter the battery module interior
Solution Approach 1:
The frame cover divides the fastening area into isolated zones using the barrier portion. This segmentation contains the foreign matter generation zone (where bolt and nut interact) separate from the battery module interior, allowing strong fastening operations without contaminating the internal space.
Solution Approach 2:
The barrier portion effectively extracts or removes the harmful effect of foreign matter generation from the battery module interior. By creating a physical separation, the design allows the bolt-nut friction process to occur without introducing contaminants into the protected internal space.
3Reliability
If the nut structure is blocked to provide insulation, then the electrical insulation is improved, but the bolt cannot be sufficiently rotated to achieve high fastening force
Solution Approach 1:
The frame cover is divided into distinct functional zones: the nut accommodation portion provides insulation and stability, while the bolt accommodation portion provides rotation space. This segmentation resolves the contradiction by allowing the nut area to be blocked for insulation while the bolt area remains open for operation.
Solution Approach 2:
Different portions of the frame cover have different structural qualities tailored to their specific functions. The nut accommodation portion has a blocked structure for insulation and stability, while the bolt accommodation portion has an open groove structure for rotation freedom. This local differentiation resolves the contradiction between insulation and operability.
4Device complexity
If the bolt accommodation space is limited, then the device complexity is reduced, but the degree of freedom in selecting bolt length is limited and sufficient rotation cannot be achieved
Solution Approach 1:
The frame cover serves multiple functions simultaneously: it provides structural support, electrical insulation, foreign matter barrier, and most importantly, a universal accommodation space that can accommodate bolts of various lengths. The bolt accommodation portion's groove structure provides a versatile space that adapts to different bolt requirements without increasing overall device complexity.
Data Source
AI summary
A battery module includes a cell stack formed by stacking a plurality of battery cells; a bus bar frame assembly having a bus bar frame configured to cover the longitudinal sides of the cell stack and a plurality of bus bars fixed on the bus bar frame and electrically connected to the battery cells; a module terminal having a lead connection fixed on the bus bar frame and electrically connected to the battery cells and a head connected to the lead connection to extend above the lead connection; a terminal nut located below the head; and a frame cover having a nut accommodation portion configured to accommodate the terminal nut and a bolt accommodation portion to accommodate a bolt passing through the head and the terminal nut, the frame cover being configured to cover the bus bar frame assembly so that the head is exposed to an outside.