Bus Bar Module Positioning to Prevent Battery Pack Misassembly
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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 process, which affects the electrical connectivity and overall performance of the battery pack.
Innovation Solution
The battery pack design incorporates bus bar modules with protrusions and positioning mechanisms that prevent incorrect assembly by interfering with each other when misaligned, ensuring correct installation through interference prevention mechanisms, such as protrusions and press-fitted positioning mechanisms between stacks, allowing only precise and correct assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the bus bar module is installed after the stack of battery cells is accommodated in the case, then the Cell-to-Pack structure is achieved, but incorrect assembling of the bus bar module may occur
Solution Approach 1:
The patent employs asymmetric positioning protrusions and corresponding recesses on the bus bar module and battery cell stack. The protrusion has a specific shape and position that only matches the recess in the correct orientation, making it impossible to assemble the bus bar module incorrectly. This asymmetric design ensures that the bus bar module can only be installed in the proper direction, preventing assembly errors while maintaining ease of manufacture.
2Reliability
If positioning mechanisms are added to prevent incorrect assembly, then assembly correctness is improved, but device complexity increases
Solution Approach 1:
The patent integrates the positioning protrusions directly into the bus bar module structure and the corresponding recesses into the battery cell stack structure. These positioning features are merged with the functional components rather than being separate auxiliary mechanisms. The protrusion and recess serve dual purposes: they provide mechanical positioning and simultaneously prevent incorrect assembly orientation, thereby improving reliability without significantly increasing device complexity.
Data Source
Figure 1
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AI summary
At least one of a first bus bar module (30A) and a second bus bar module (30B) has a protrusion (330A, 330B, 340A, 340B) that protrudes toward the other of the first bus bar module (30A) and the second bus bar module (30B), the protrusion (330A, 330B, 340A, 340B) hindering incorrect assembling of the first bus bar module (30A) or the second bus bar module (30B) by interference, the protrusion (330A, 330B, 340A, 340B) causing no interference when the first bus bar module (30A) and the second bus bar module (30B) are correctly assembled.