Busbar Alignment Guides for Battery Pack Thermal Barrier Assembly
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Solution Overview
Problem
The assembly of battery packs is challenging due to the need for precise alignment and integration of thermal barriers with busbars and isolation covers, which is time-consuming and labor-intensive, affecting manufacturing efficiency and thermal management.
Innovation Solution
The busbar and isolation cover are designed with flared guide profiles in their channels to facilitate the self-alignment of thermal barriers, ensuring proper positioning and reducing manual intervention during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual alignment methods are used to position thermal barriers in battery packs, then assembly precision can be achieved, but assembly time and labor intensity increase significantly
Solution Approach 1:
The busbar channels are pre-designed with flared guide profiles that create self-alignment features during the assembly process. The thermal barriers are guided into the correct position by the flared shape of the channel openings, which automatically align them with the channel axes before insertion. This preliminary alignment action eliminates the need for manual positioning adjustments during assembly.
Solution Approach 2:
The flared guide profiles in the busbar channels provide self-aligning functionality, where the thermal barriers automatically position themselves correctly during insertion without requiring external alignment tools or manual intervention. The geometry of the flared channels serves the dual purpose of guiding and securing the thermal barriers in their proper positions.
2Reliability
If complex alignment procedures are implemented to ensure proper positioning of thermal barriers, then assembly reliability improves, but the complexity of the assembly process increases
Solution Approach 1:
The flared guide profiles are implemented locally at the opening portions of the busbar channels, providing self-alignment functionality only where it is most needed during the insertion process. The majority of the channel maintains its standard geometry for thermal barrier accommodation, thus adding minimal structural complexity while achieving reliable alignment.
3Manufacturing precision
If precise manual positioning of thermal barriers is performed, then thermal management performance is optimized, but manufacturing time is extended
Solution Approach 1:
The manual mechanical positioning process is replaced by a geometric guiding system. The flared channel profiles substitute for manual alignment operations, using the shape of the channels to automatically position thermal barriers correctly during insertion, thereby eliminating time-consuming manual positioning while maintaining precision.
Data Source
AI summary
The present disclosure provides a busbar for a battery pack having a plurality of battery cells separated by respective thermal barriers. The busbar is configured to provide electrical connection between battery cells within the battery pack by way of electrical connection arrangements. The busbar further comprises a plurality of channels, each channel configured to receive a thermal barrier. Each channel includes a first portion sized to accommodate a thermal barrier and a second portion adjacent an opening of the channel which is wider than the first portion of the channel such that, during assembly of the busbar into a battery pack, the second portion of each channel is configured to guide a thermal barrier into the respective channel.