Integrated Busbar Bracket Split Structure for Easier CCS Replacement

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Solution Overview

Problem

The CCS assembly process in existing battery technologies is cumbersome, has a long processing cycle, and incurs high processing costs due to the need for different molds and UV glue for coverage.

Innovation Solution

The integrated busbar is designed with a split structure comprising a mounting bracket and an installation bracket, allowing flexible adjustment and replacement of parts, reducing disassembly difficulties and costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If an integral one-piece tray design is used, then structural strength and stability are improved, but ease of repair and replacement deteriorate

Engineering Contradiction:

Improvestructural strengthVSAvoidease of replacement

Core Design Contradiction:

StrengthVSEase of repair

Solution Approach 1:

The integrated busbar bracket is divided into multiple independent components including a mounting bracket, installation bracket, and connecting components. This segmentation allows individual parts to be replaced without replacing the entire bracket structure, improving ease of repair while maintaining overall structural integrity through the connecting components.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If different molds are used for different CCS structures, then adaptability to different battery configurations is improved, but device complexity and manufacturing cost worsen

Engineering Contradiction:

Improveadaptability to different CCS structuresVSAvoidnumber of molds required

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The mounting bracket and installation bracket are designed as universal components that can accommodate different CCS (Collection Contact System) structures through adjustable positioning features and standardized connection interfaces. This allows a single bracket design to serve multiple battery configurations, reducing the need for different molds while maintaining adaptability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The bracket incorporates adjustable and reconfigurable elements that allow it to adapt dynamically to different CCS structures. The connecting components enable reconfiguration of the bracket layout to match various battery cell arrangements, eliminating the need for dedicated molds for each configuration.

Inventive Principle:

Principle #15Dynamics

3Reliability

If UV glue is used for coverage and protection, then protective coverage is improved, but processing cycle time worsens

Engineering Contradiction:

Improveprotective coverageVSAvoidprocessing cycle time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent extracts the protective function from the UV glue coating process and integrates it into the mechanical structure of the bracket itself. The bracket design incorporates built-in protective features such as integrated shielding elements and structural coverage, eliminating the need for separate UV glue application and curing steps, thereby reducing processing time while maintaining protective coverage.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS20250316852A1Integrated busbar, bracket thereof, and battery module thereof

Publication Date: 2025.10.09 EVE ENERGY CO LTD

AI summary

The present application provides an integrated busbar, and a bracket of the integrated busbar, and a battery module of the integrated busbar. The integrated busbar includes a bus assembly and an integrated busbar bracket. The bus assembly is configured to be electrically connected to a plurality of battery cells. The integrated busbar bracket includes a mounting bracket and an installation bracket configured as split structures. Two ends of the bus assembly are installed on the mounting bracket. A middle part of the bus assembly is installed on the installation bracket.