Bus Bar Module Positioning in Cell-to-Pack Battery Packs
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Solution Overview
Problem
In the Cell-to-Pack battery structure, there is no binding bar to facilitate precise positioning of bus bar modules, requiring a different mechanism for accurate placement.
Innovation Solution
A battery pack design that includes a positioning mechanism with an inserted portion between stacks to precisely position bus bar modules, utilizing a press-fitted mechanism with asymmetrical or symmetrical shapes and protrusions to align the bus bar modules in the orthogonal direction, allowing for precise electrical connections without the need for binding bars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a module structure with binding bars is used to position bus bar modules, then precise positioning is achieved, but device complexity increases due to additional components
Solution Approach 1:
The invention extracts the positioning function from the traditional binding bar mechanism and integrates it directly into the case structure through inserted portions. This eliminates the need for separate binding bars while maintaining precise positioning capability, thereby reducing device complexity while preserving positioning precision.
Solution Approach 2:
The case structure is merged with the positioning function by incorporating inserted portions that extend between battery cell stacks. This combines the housing and positioning mechanisms into a single integrated structure, eliminating separate positioning components and reducing overall device complexity.
2Device complexity
If a Cell-to-Pack structure without binding bars is used, then device complexity is reduced, but positioning precision of bus bar modules deteriorates
Solution Approach 1:
The inserted portions of the case act as intermediary elements between the battery cell stacks and the bus bar modules. These intermediaries provide precise positioning surfaces and geometric constraints that guide bus bar module placement, achieving accurate positioning without requiring additional binding bar components.
Solution Approach 2:
The case structure is pre-configured with inserted portions that create predetermined positioning locations for bus bar modules. This preliminary arrangement of geometric constraints ensures that when bus bar modules are installed, they automatically achieve precise positioning without requiring additional positioning components or complex assembly procedures.
Data Source
AI summary
At least one of a first bus bar module and a second bus bar module has a positioning mechanism that is inserted between a first stack and a second stack and that positions the first bus bar module or the second bus bar module in a direction (second direction) orthogonal to a stacking direction (first direction) of battery cells.