Bus Bar Module Protrusions for Error-Proof Battery Pack Assembly
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Solution Overview
Problem
In the Cell-to-Pack battery structure, incorrect assembly of bus bar modules can occur due to misalignment or improper installation direction during the mounting of bus bar modules after the battery cell stack is accommodated in a case.
Innovation Solution
The battery pack design incorporates bus bar modules with protrusions that interfere with incorrect assembly, featuring a positioning mechanism that ensures correct alignment and installation direction, using protrusions and press-fitted components to prevent misalignment and provide a precise positioning system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If bus bar modules are installed after the battery cell stack is accommodated in a case, then the Cell-to-Pack structure is achieved, but incorrect assembling of the bus bar module in terms of type or installation direction may occur
Solution Approach 1:
The patent applies asymmetry by providing protrusions on bus bar modules that have specific directional orientations. These protrusions are asymmetric in shape and position, allowing the bus bar module to be installed only in the correct orientation. The protrusions prevent installation in wrong directions or with incorrect types, thus ensuring assembly reliability while maintaining the Cell-to-Pack structure ease of manufacture.
2Reliability
If protrusions are added to bus bar modules to prevent incorrect assembling, then assembly reliability is improved, but device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the positioning function into separate protrusion elements on the bus bar module. These protrusions are discrete, localized features rather than a complex overall structure. This segmented approach prevents incorrect assembly while adding minimal complexity to the bus bar module design.
Data Source
AI summary
At least one of a first bus bar module and a second bus bar module has a protrusion that protrudes toward the other of the first bus bar module and the second bus bar module, the protrusion hindering incorrect assembling of the first bus bar module or the second bus bar module by interference, the protrusion causing no interference when the first bus bar module and the second bus bar module are correctly assembled.