Connection Module Bus Bar Clearance for Battery Assembly Errors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connection modules fail to attach correctly to electricity storage element groups due to dimensional differences between electrode terminals and bus bars, leading to positional displacement and potential attachment failures.
Innovation Solution
A connection module with a bus bar and insulating protector, featuring a clearance between retaining portions and the bus bar, allowing for inclination and absorption of positional displacement, and coupling portions that expand or contract to accommodate dimensional errors in the arrangement direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bus bar is rigidly fixed to the electrode terminals, then the electrical connection is stable, but the attachment fails when dimensional errors cause positional displacement
Solution Approach 1:
The bus bar is designed with flexibility to allow positional adjustment within a predetermined range, transforming from a rigid fixed structure to a dynamic adaptable one. This enables the bus bar to accommodate dimensional errors in electrode terminals while maintaining electrical connection reliability.
Solution Approach 2:
The physical state of the bus bar is changed from rigid to flexible, allowing it to deform and adapt to positional variations. This parameter change enables the bus bar to absorb dimensional errors without requiring complex adjustment mechanisms.
2Reliability
If the bus bar is made flexible to accommodate positional displacement, then attachment reliability improves, but the electrical connection stability deteriorates
Solution Approach 1:
The bus bar is made flexible only within a predetermined limited range, not completely flexible. This partial flexibility allows accommodation of dimensional errors while maintaining sufficient stiffness to ensure stable electrical connection, avoiding excessive deformation that would compromise connection quality.
3Adaptability or versatility
If the substrate portion is provided with a slit for adjusting inter-electrode pitches, then adaptability to dimensional variations improves, but the structural strength deteriorates
Solution Approach 1:
The substrate portion is divided into a slit region that can be bent for adjusting inter-electrode pitches, while other regions maintain full strength. This segmentation allows localized flexibility where needed while preserving overall structural integrity.
Solution Approach 2:
The substrate portion transitions from a completely rigid structure to one with dynamic adjustable regions. The slit enables the substrate to adapt to different inter-electrode pitches by bending, providing flexibility without compromising the strength of the entire substrate.
4Manufacturing precision
If the bus bar is positioned precisely relative to electrode terminals, then manufacturing precision is high, but the ease of manufacture decreases due to strict tolerance requirements
Solution Approach 1:
The bus bar's flexibility eliminates the need for high-precision positioning during assembly. The bus bar can be installed in a approximate position and then adjusted within its flexible range to achieve proper alignment, significantly easing manufacturing requirements while maintaining final positioning precision.
Data Source
AI summary
A connection module can be attached to an electricity storage element group in which a plurality of electricity storage elements each including a positive and a negative electrode terminal are aligned, the connection module including: a bus bar including a pair of terminal connection portions that are to be respectively connected to the electrode terminals of the adjacent electricity storage elements; and an insulating protector that is to be fixed to the electricity storage element group, wherein the insulating protector includes an accommodation frame inside of which the bus bar is disposed; and retaining portions that prevent the bus bar from coming off in the left-right direction inside the accommodation frame, and a tolerance absorbing clearance is provided between each of the retaining portions and the bus bar.