Bus Bar Connection Using Spacer Projections for Battery Assembly
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Solution Overview
Problem
Conventional methods for connecting bus bars to external terminals of electric storage elements often require precise alignment, which can be challenging due to machining inaccuracies, leading to potential misalignment and failure in connection, especially when the elements are pre-positioned, necessitating adjustments that complicate the manufacturing process.
Innovation Solution
A method involving a resin member, such as a spacer, with projections and receiving portions that align with the bus bar's projections and receiving portions, ensuring consistent positional relationships between the external terminals and the bus bar, allowing for appropriate connection without additional machining steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a projection and receiving portion method is used to position the bus bar relative to the electric storage element, then the positioning accuracy is improved, but the device complexity increases due to additional structural components
Solution Approach 1:
The patent combines the spacer (resin member) with the bus bar structure by integrating the receiving portion directly into the bus bar assembly. The spacer has projections that fit into receiving portions on the bus bar, merging the positioning function with the electrical connection function, thereby reducing overall device complexity while maintaining positioning accuracy
Solution Approach 2:
The resin member (spacer) acts as an intermediary component between the electric storage element and the bus bar. It provides the projection-receiving portion interface that enables precise positioning without requiring direct complex machining between the main components, thus improving positioning accuracy while keeping the overall structure manageable
2Productivity
If the electric storage element is pre-positioned, then the manufacturing efficiency is improved, but the manufacturing precision deteriorates due to inability to adjust alignment
Solution Approach 1:
The spacer is pre-positioned on the electric storage element with its projections already aligned to receive the bus bar. This preliminary positioning action allows the bus bar to be subsequently connected without requiring adjustment, maintaining both manufacturing efficiency and precision
Solution Approach 2:
The projection-receiving portion structure enables self-alignment between the bus bar and electric storage element. The geometry of the projections and receiving portions automatically guides correct positioning during assembly, eliminating the need for external adjustment operations while maintaining high alignment accuracy
3Manufacturing precision
If additional machining steps are performed to ensure proper alignment, then the manufacturing precision is improved, but the device complexity and manufacturing time increase
Solution Approach 1:
The receiving portions are pre-formed on the bus bar and the projections are pre-formed on the spacer during the manufacturing of these components. This preliminary preparation of positioning features eliminates the need for additional machining steps during assembly, maintaining high precision while reducing process complexity
Solution Approach 2:
The patent replaces complex mechanical alignment and adjustment mechanisms with a simple geometric interlocking system using projections and receiving portions. This substitution achieves high alignment precision through form-fit rather than through complex mechanical adjustment systems
Data Source
AI summary
A method for producing an electric storage device having a bus bar and an electric storage element equipped with an external terminal includes the steps of: arranging the electric storage element having the external terminal, positioning a resin member having either one of a receiving portion or a projection relative to the electric storage element, arranging the bus bar having the other one of the receiving portion or the projection on the external terminal, connecting the bus bar to the external terminal, and inserting the projection into the receiving portion in the step of arranging the bus bar.