Integrated Busbar Frame Cell Module Assembly for Faster Battery Loading
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Solution Overview
Problem
Conventional cell module assemblies require complex and time-consuming assembly processes, involving the alternated stacking of battery cells, cartridges, and end covers, with the busbar unit being coupled afterwards, which can lead to incorrect assembly and increased reassembly time.
Innovation Solution
A cell module assembly design where a U-shaped case with a busbar unit integrally coupled to its front and rear receives battery cells, with the busbar unit featuring a bent frame to facilitate easy insertion and removal of cells, and a cover plate that can be easily detached for inspection and measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery cells, cartridges, and end covers are alternately stacked and busbar unit is coupled afterwards, then the cell module assembly can be assembled, but the assembly process becomes complicated and time-consuming
Solution Approach 1:
The busbar unit is integrally coupled to the case as a single integrated structure, merging two previously separate components (case and busbar unit) into one. This integration eliminates the need for separate coupling steps, simplifies the assembly process, and reduces assembly time while maintaining assembly correctness.
Solution Approach 2:
The busbar unit is pre-coupled to the case before battery cells are installed. This preliminary action ensures that the electrical connection structure is already in place and properly positioned, guiding correct assembly of subsequent components and reducing reassembly needs.
2Reliability
If busbar unit is coupled to stacked battery cells and cartridges, then electrical connection is achieved, but the process requires complex multi-step assembly
Solution Approach 1:
The case and busbar unit are merged into a single integrated component. The busbar unit is fixed to the case in advance, forming an integrated structure that reduces the number of assembly steps and simplifies the overall assembly process while ensuring reliable electrical connection.
Solution Approach 2:
The integrated case-busbar unit serves multiple functions simultaneously: it provides structural enclosure (case function) and electrical connection (busbar function). This multi-functionality reduces the number of separate components needed and simplifies the assembly process.
3Ease of manufacture
If conventional stacking method is used, then battery cells can be assembled, but reassembly time increases when wrong assembly occurs
Solution Approach 1:
The busbar unit is pre-installed on the case before battery cells are placed. This preliminary configuration creates a guided assembly sequence where battery cells are inserted into predetermined positions, reducing the likelihood of incorrect assembly and minimizing reassembly time if errors occur.
Solution Approach 2:
The assembly process is segmented into distinct sequential steps: first coupling the busbar unit to the case, then inserting battery cells into the predefined spaces. This segmentation creates a clear assembly sequence that reduces errors and facilitates quick identification of assembly mistakes.
Data Source
AI summary
A cell module assembly includes a plurality of battery cells, each of the battery cells having electrode leads, a case configured to receive the battery cells, a cover plate located at an open upper surface of the case so as to be coupled to the case, and a busbar unit located at the front and the rear of the case, from which the electrode leads of the received battery cells protrude. The case is configured to have a U shape in which a base plate defining a bottom surface of the case and side plates defining opposite side surfaces of the case are coupled to each other, and the busbar unit includes a busbar frame, one side of which is bent, whereby a process of manufacturing the cell module assembly is simplified and the battery cells are easily received in the case.