Busbar Clamping and Guiding Structure for Tab Terminal Alignment
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Solution Overview
Problem
Existing busbar assembly processes in electrified vehicles face challenges in properly positioning and aligning tab terminals of battery cells relative to busbars, which is crucial for reliable electrical connections.
Innovation Solution
A busbar module with clamping and guiding features, including a busbar frame with projections and ramped surfaces, facilitates the alignment and secure connection of tab terminals to busbars through slots and welds, ensuring precise positioning and stable electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional busbar assembly processes are used, then the assembly process is simple, but the positioning and alignment of tab terminals relative to busbars is difficult to achieve precisely
Solution Approach 1:
The patent introduces a positioning structure as an intermediary component between the busbar and tab terminal. This positioning structure includes positioning protrusions that fit into corresponding positioning grooves, serving as a mediator to achieve precise alignment without requiring complex external fixtures or assembly procedures.
Solution Approach 2:
The busbar assembly is segmented into distinct functional components: the busbar body, the positioning structure with protrusions and grooves, and the tab terminal. This segmentation allows each component to be optimized independently for its specific function while maintaining overall assembly precision through the standardized positioning interface.
2Reliability
If traditional busbar assembly processes are used, then the device structure is simple, but the electrical connection reliability is compromised
Solution Approach 1:
The positioning structure performs preliminary alignment action before the final welding or connection process. The positioning protrusions and grooves pre-establish the correct relative position between busbar and tab terminal, ensuring that when the connection is made, the electrical contact occurs at the optimal location for maximum reliability.
Solution Approach 2:
The positioning structure acts as an intermediary that ensures consistent and reliable positioning during assembly. By providing a standardized mechanical interface, it eliminates variability in alignment that would otherwise compromise electrical connection reliability, while the structure itself remains relatively simple.
3Manufacturing precision
If manual alignment methods are used, then the assembly process is simple, but the alignment precision of tab terminals is insufficient
Solution Approach 1:
The positioning structure enables self-alignment during assembly. The positioning protrusions and grooves are designed to guide the tab terminal into the correct position automatically as components are brought together, eliminating the need for manual measurement or adjustment while maintaining high alignment precision.
Solution Approach 2:
The positioning structure serves as a mediator that translates the rough positioning from manual handling into precise final alignment. The mechanical interface of protrusions and grooves provides a deterministic positioning mechanism that works consistently regardless of operator skill level, maintaining both precision and productivity.
Data Source
AI summary
A battery pack may include a busbar including a slot. The battery pack may further include a battery cell including a housing and a tab terminal extending from the housing. The tab terminal may be received within the slot such that at least a portion of the tab terminal is positioned on an opposite side of the busbar from the housing. The battery pack may additionally include a busbar frame including a projection. The projection may be received within the slot such that at least a portion of the projection is positioned on the opposite side of the busbar from the housing.