Busbar Case Terminal Alignment for Battery Module Compression
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Solution Overview
Problem
Existing secondary battery modules face challenges in maintaining the fixed positions of batteries during compression, as the size of the battery laminate changes before and after assembly, leading to difficulties in arranging batteries without them becoming dislodged.
Innovation Solution
A secondary battery module design featuring a busbar case with specific hole configurations and terminal insertion mechanisms, where the sum of gaps between terminals and hole ends satisfies a particular formula, ensuring terminals remain aligned and fixed even with size changes during compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If secondary batteries are arranged by inserting terminals into holes of the busbar case, then the terminals can be positioned, but the positions of the terminals change when the secondary battery laminate is compressed, making it difficult to dispose the secondary batteries at their fixed positions
Solution Approach 1:
The busbar case is designed with predetermined gaps (E and F) that are calculated in advance based on the expected compression amount (A-B). These gaps are built into the structure before compression occurs, allowing the terminals to be inserted at the correct positions before compression and remain at those positions after compression, as the gaps compensate for the dimensional change.
Solution Approach 2:
The design accounts for the parameter change in the laminate thickness (from A to B) by incorporating compensatory gaps in the busbar case. The gap dimensions are specifically designed to match the expected compression amount, transforming the dimensional change from a problematic variable into a controlled design parameter that maintains positioning accuracy.
2Ease of manufacture
If insulating material with guide walls is used to arrange secondary batteries, then the batteries can be positioned, but replacing it with inexpensive sheet material makes it difficult to arrange the secondary batteries without them getting out of position
Solution Approach 1:
The positioning function is extracted from the insulating material and transferred to the busbar case. Instead of relying on the insulating material to provide guide walls for positioning, the busbar case with its precisely designed holes and gaps assumes the positioning responsibility, allowing the insulating material to be simplified to inexpensive sheet material.
Solution Approach 2:
The busbar case acts as an intermediary structure that mediates between the secondary batteries and the simplified insulating material. It provides the necessary positioning and guidance functions that would otherwise require complex insulating material, enabling the use of simple sheet material while maintaining positioning accuracy.
Data Source
AI summary
A secondary battery module incudes a secondary battery, a secondary battery laminate, a busbar, and one pair of lashing plates. The one pair of lashing plates is provided on either end of the secondary battery laminate in a laminating direction. The one pair of lashing plates is connected via a cell block provided so as to face the narrow surface of the secondary battery. The secondary battery laminate is lashed in a state of being pressed in the laminating direction.