Bus Bar Frame Guide Structure for Faster Battery Module Assembly
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Solution Overview
Problem
Existing battery module assembly processes face difficulties due to misalignment or improper coupling of cell stacks and bus bar assemblies, leading to inefficiencies and increased manufacturing time.
Innovation Solution
A battery module design featuring a bus bar frame with inclined guide portions and a module frame structure that facilitates smooth insertion of electrode leads, along with heat dissipation paths through a connection plate and frame cover, enhancing assembly efficiency and heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bus bar assembly is coupled to a cell stack during manufacturing, then electrical connection is established, but assembly difficulty increases when misalignment occurs
Solution Approach 1:
The bus bar frame acts as an intermediary component between the bus bar and the cell stack. It provides guide portions that facilitate proper alignment of electrode leads with through-slits, and includes through-holes that accommodate the electrode leads during the coupling process, thereby easing assembly while maintaining reliable electrical connection.
2Reliability
If electrode leads are inserted into through-slits of bus bar, then electrical connectivity is achieved, but misalignment causes assembly difficulty
Solution Approach 1:
The bus bar frame's guide portions are designed in advance to extend toward the through-slits of the bus bar, creating a preliminary alignment path. This preliminary action guides the electrode leads into the correct position before they reach the through-slits, reducing the precision requirements during the final insertion step.
Solution Approach 2:
The guide portions of the bus bar frame serve as an intermediary alignment mechanism between the electrode leads and the through-slits. They provide a transitional path that facilitates accurate positioning, thereby improving manufacturing precision during assembly.
3Productivity
If multiple electrode leads are inserted simultaneously, then assembly time is reduced, but alignment control becomes more difficult
Solution Approach 1:
The bus bar frame is segmented with multiple through-holes, each corresponding to an electrode lead. The guide portions are also segmented to individually guide each electrode lead. This segmentation allows multiple leads to be inserted simultaneously while maintaining individual alignment control for each lead.
Data Source
AI summary
A battery module including a cell stack including a plurality of battery cells that are stacked on top of one another, the plurality of battery cells including electrode leads, at least one bus bar structured to provide a plurality of through-slits into which the electrode leads are inserted, and a bus bar frame coupled to the at least one bus bar, the bus bar frame having a plurality of through-holes in which the electrode leads are disposed. Each of the through-slits may include a first guide portion structured to include a first space wider than a width of a corresponding through-slit for a corresponding electrode lead to be inserted toward the through-slit, and the bus bar frame may include a second guide portion structured to include a second space that extends from the first space and has a width wider than the first space.