Integrated Busbar Cover Plate Layout for Battery Module Assembly Tolerance
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Solution Overview
Problem
The compatibility and assembly tolerance of large battery modules with integrated busbar cover plates are poor due to the large size and increased tolerance of the cover plate, leading to interference between the poles of the batteries and the limiting through holes during installation.
Innovation Solution
The design includes varying the length of limiting through holes on the integrated busbar cover plate, with longer holes at the ends to accommodate the poles, reducing interference and improving compatibility by using the middle holes as a reference for alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the integrated busbar cover plate is made large in size to accommodate multiple batteries, then the coverage and structural support are improved, but the assembly tolerance and compatibility deteriorate due to increased tolerance accumulation
Solution Approach 1:
The patent divides the integrated busbar cover plate into multiple modular units, each with its own limiting through holes. This segmentation allows each module to be manufactured with tighter tolerances independently, avoiding the tolerance accumulation that would occur in a single large cover plate. The modular units can then be assembled together to form the complete battery module structure.
Solution Approach 2:
The patent applies different hole length specifications to different regions of the cover plate. Limiting through holes near the ends of the battery module are designed with greater length to accommodate larger positioning tolerances of battery poles in those regions. This local differentiation of hole quality resolves the contradiction by providing enhanced tolerance compensation exactly where needed, rather than requiring the entire cover plate to be oversized.
2Quantity of substance
If the cover plate size is increased to fit more batteries, then the battery module capacity is improved, but the interference between poles and limiting through holes increases during installation
Solution Approach 1:
The patent implements local quality by varying the length of limiting through holes based on their position on the cover plate. Holes located near the ends of the battery module are made longer to provide sufficient clearance for battery pole insertion, preventing interference during assembly. This localized adjustment allows the cover plate to accommodate more batteries without increasing interference issues.
Solution Approach 2:
The patent changes the geometric parameters of the limiting through holes, specifically the length parameter, to resolve the interference problem. By increasing the length of holes in specific locations where interference is most likely to occur, the design accommodates the full range of acceptable pole positioning variations while maintaining the ability to fit multiple batteries in the module.
Data Source
Figure 1~2a
Figure 2b~3a
Figure 3b~5
AI summary
Disclosed is a battery module, including batteries arranged along a first direction that is a thickness direction of the battery and an integrated busbar cover plate. The integrated busbar cover plate is disposed at tops of the batteries. Limiting through hole groups arranged at intervals along the first direction are provided on the integrated busbar cover plate, correspond to the batteries one by one, and are matched with poles of corresponding batteries. In the first direction, a length of a limiting through hole in the limiting through hole group near an end part of the integrated busbar cover plate is greater than that of a limiting through hole in the limiting through hole group located in a middle part of the integrated busbar cover plate. The length of the limiting through hole is a size of the limiting through hole along the first direction.