Battery Module Bus Bar Guide Couplings for Lead Alignment
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Solution Overview
Problem
Conventional battery module assembly processes face inefficiencies due to alignment errors and the need for bending electrode leads before welding, which degrades weldability and overall assembly efficiency.
Innovation Solution
The battery module employs block bus bars with guide couplings that protrude along the stacking direction, allowing for precise alignment and electrical connection of electrode leads without pre-bending, improving weldability and assembly efficiency by coupling guide couplings during the stacking process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electrode leads are bent into a predetermined shape through a bending process before welding, then the electrode leads can be connected to the bus bar, but the weldability is degraded and the assembly process becomes more complex
Solution Approach 1:
The bus bar is designed with guide couplings that protrude along the stacking direction, which preliminarily guide and position the electrode leads before welding occurs. This preliminary guidance action eliminates the need for complex bending processes and improves weldability by ensuring proper alignment is achieved through the guide couplings rather than pre-bending the electrode leads
2Manufacturing precision
If cell cartridges or battery cells are stacked without alignment guidance, then the assembly process is simple, but alignment errors occur that degrade assembly and weldability
Solution Approach 1:
The guide couplings on the bus bar perform the alignment function automatically during the stacking process. As cell cartridges are stacked, the guide couplings self-guidе the electrode leads into proper alignment without requiring external alignment tools or complex positioning mechanisms, thereby achieving high alignment precision while maintaining assembly efficiency
Solution Approach 2:
The guide couplings act as an intermediary element between the bus bar and the electrode leads. These couplings provide a mechanical interface that ensures precise alignment during stacking, mediating the connection between components and preventing alignment errors that would otherwise require complex external alignment procedures
3Power
If multiple battery cells are connected in series or parallel to configure a battery pack, then the required output voltage and charge/discharge capacity are achieved, but the number of components and assembly complexity increases
Solution Approach 1:
The bus bar with guide couplings serves multiple functions simultaneously: it provides electrical connection for series/parallel configuration of battery cells, provides alignment guidance through protruding guide couplings, and facilitates efficient assembly. This multi-functionality reduces the need for separate alignment components and simplifies the overall assembly process despite the increased number of battery cells
Data Source
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AI summary
A battery module includes battery cells stacked to be electrically connected to each other, cell cartridges configured to cover protruding portions of a pair of electrode leads of the battery cells and arranged along a stacking direction of the battery cells, and block bus bars respectively provided to the cell cartridges and respectively electrically connected to the electrode leads, the block bus bars having a guide coupling formed on at least one side thereof to protrude along the stacking direction.