Bus Bar Module Positioning in Compact Battery Cell Stacks
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Solution Overview
Problem
Conventional battery assemblies face challenges in precisely positioning bus bar modules while maintaining sufficient installation space for battery cells, which affects energy density.
Innovation Solution
A battery assembly design that includes a fitting member with an engagement portion to secure the bus bar module, utilizing a thin sheet member with a protrusion that engages with the bus bar module, allowing precise positioning without reducing the installation space for battery cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a positioning mechanism is provided to precisely position the bus bar module, then positioning precision is improved, but the installation space for battery cells is reduced
Solution Approach 1:
The fitting member integrates multiple functions: it positions the bus bar module in the first direction through the engagement portion, prevents displacement in the second direction through the fitted structure, and maintains electrical insulation. By combining positioning, fixation, and insulation functions into a single component, the design achieves precise positioning without requiring separate structures that would consume additional installation space.
Solution Approach 2:
The fitting member is constituted as a thin sheet member with a thickness of 0.5 mm or less. This thin-film approach provides the necessary positioning and fixation functionality while occupying minimal space, thereby preserving the installation space for battery cells while achieving the required positioning precision.
2Manufacturing precision
If a positioning mechanism is provided to precisely position the bus bar module, then positioning precision is improved, but the device complexity is increased
Solution Approach 1:
The fitting member integrates multiple functions: it positions the bus bar module in the first direction through the engagement portion, prevents displacement in the second direction through the fitted structure, and maintains electrical insulation. By combining positioning, fixation, and insulation functions into a single component, the design achieves precise positioning without requiring separate structures that would consume additional installation space.
Solution Approach 2:
The fitting member serves multiple purposes simultaneously: it acts as a positioning element, a fixation element, and an insulating element. This multi-functionality reduces the overall number of components needed in the battery assembly, thereby simplifying the device structure while maintaining precise positioning capability.
3Strength
If a thick fitting member is used to ensure structural strength, then strength is improved, but the installation space for battery cells is reduced
Solution Approach 1:
The fitting member is constituted as a thin sheet member with a thickness of 0.5 mm or less. This thin-film approach provides the necessary positioning and fixation functionality while occupying minimal space, thereby preserving the installation space for battery cells while achieving the required positioning precision.
Solution Approach 2:
The fitting member is made of an insulating material that provides both mechanical strength and electrical insulation properties. By selecting appropriate insulating materials with sufficient mechanical properties, the design achieves the required structural strength without needing to increase the thickness of the fitting member, thus maintaining compact dimensions.
Data Source
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AI summary
A battery assembly includes: a stack (10) including a plurality of battery cells (100) arranged side by side in a first direction; a bus bar module (30) provided on the stack (10); and a fitting member (40) fitted to an end portion of a housing (120) of at least one of the plurality of battery cells (100) in a second direction orthogonal to the first direction. The fitting member (40) has an engagement portion (41), and the engagement portion (41) is engaged with the bus bar module (30) so as to position the bus bar module (30) with respect to the stack (10) at least in the first direction.