Battery Pack Bus Bar Positioning for Precise Substrate Assembly
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Solution Overview
Problem
The Cell-to-Pack structure in battery packs lacks a binding mechanism to precisely position a substrate case, complicating the manufacturing process due to the absence of binding bars.
Innovation Solution
A precise positioning mechanism for the substrate case is implemented using bus bar modules with protuberances and insertion mechanisms, ensuring accurate alignment in the X and Y axes, and claw and wall portions to secure the substrate unit, simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a Cell-to-Pack structure is employed without binding bars, then the manufacturing process is simplified and the structure is more compact, but the positioning precision of the substrate case deteriorates
Solution Approach 1:
The invention divides the positioning function into multiple independent positioning structures: positioning protrusions on the bus bar module that fit into positioning recesses on the substrate case, and additional positioning protrusions on the case that fit into positioning recesses on the substrate case. This segmentation allows each positioning element to contribute to overall positioning precision without requiring complex binding bar structures.
Solution Approach 2:
The invention introduces positioning protrusions and positioning recesses as intermediary elements between the bus bar module, case, and substrate case. These intermediary positioning features mediate the positioning relationship, enabling precise alignment without direct mechanical connection through binding bars.
2Manufacturing precision
If binding bars are used for positioning the substrate case, then positioning precision is improved, but the device complexity increases
Solution Approach 1:
The invention extracts the positioning function from the binding bar structure and implements it through dedicated positioning protrusions and positioning recesses on the bus bar module and case. This separation allows the positioning function to be achieved independently without requiring complex binding bar mechanisms.
Solution Approach 2:
Instead of using binding bars to actively constrain the substrate case, the invention uses passive positioning protrusions and recesses that guide and position components through their geometric interfit, inverting the traditional active constraint approach.
Data Source
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AI summary
A battery pack (1) includes: a stack (10) including a plurality of battery cells (100) arranged side by side in a first direction; a case (20) that has a side wall (21) facing the stack (10) in the first direction and that accommodates the stack (10); a bus bar module (30) including a bus bar (320) and a plate member (310), the bus bar (320) being disposed on the stack (10), the bus bar (320) electrically connecting the plurality of battery cells (100), the plate member (310) accommodating the bus bar (320); an electrical device (40) arranged side by side with the stack (10) along a second direction orthogonal to the first direction; and a substrate unit (60) at least partially disposed on the bus bar module (30) and including a substrate electrically connected to the stack (10), wherein the bus bar module (30) has a positioning mechanism (340) for the substrate unit (60), and the substrate unit (60) is fastened to the electrical device (40).