Busbar holder assembly, battery module including same, and method of manufacturing same
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Solution Overview
Problem
The existing manufacturing processes for temperature sensor assemblies in battery modules face challenges such as high defect rates and prolonged manufacturing times, which affect the efficiency and cost-effectiveness of battery module production.
Innovation Solution
A busbar holder assembly is designed to include a temperature sensor cover with a second fastening portion and an elastic member between the circuit board and the temperature sensor cover, allowing for efficient fixation of the temperature sensor assembly to the busbar holder using a first fastening portion with a recessed shape corresponding to the protruding shape of the second fastening portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing manufacturing processes are used for temperature sensor assemblies, then manufacturing experience and conventional methods are applied, but high defect rates and prolonged manufacturing times occur
Solution Approach 1:
The temperature sensor assembly is divided into separate components: the temperature sensor, the circuit board, the temperature sensor cover, and the busbar holder. These segmented parts are manufactured independently and then assembled, allowing for specialized manufacturing processes for each component and reducing defects in the final assembly.
Solution Approach 2:
The temperature sensor cover is pre-formed with a second fastening portion that includes a protruding shape, and the busbar holder is pre-formed with a first fastening portion that includes a recessed shape. These preliminary structural preparations enable quick and accurate assembly without requiring complex manufacturing processes during final assembly, thereby reducing manufacturing time and defects.
2Ease of manufacture
If conventional assembly methods are used, then traditional manufacturing approaches are applied, but assembly complexity and manufacturing time increase
Solution Approach 1:
The fastening function is merged into the structural design of the temperature sensor cover and busbar holder through the protruding and recessed shapes. This integration eliminates the need for separate fastening mechanisms or additional assembly steps, simplifying the overall assembly process while maintaining structural integrity.
Solution Approach 2:
The protruding shape of the second fastening portion and the recessed shape of the first fastening portion are designed to automatically align and engage with each other during assembly. This self-aligning and self-fastening mechanism reduces the need for precise manual positioning and complex assembly operations, making the manufacturing process easier and faster.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces the defect rate and manufacturing time for temperature sensor assemblies, thereby optimizing resource utilization and improving the overall efficiency of battery module production.
Implementation Method 1
an elastic member between the circuit board and the temperature sensor cover
Data Source
AI summary
A battery module includes battery cells, busbars electrically connecting the battery cells, a circuit board including a temperature sensor assembly, and electrically connected to the busbars, and a busbar holder for supporting the busbars, defining a receiving hole for receiving the temperature sensor assembly, and including a first fastening portion adjacent to the receiving hole, wherein the temperature sensor assembly includes a temperature sensor configured to measure a temperature of at least one of the battery cells, a temperature sensor cover including a second fastening portion configured to be fastened to the first fastening portion, and an elastic member between the circuit board and the temperature sensor cover.