Busbar Bracket Notch Layout for Easier Battery Tab Assembly
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Solution Overview
Problem
The difficulty in assembling busbar assemblies with battery cell units due to obstructed line of sight, making it challenging to confirm accurate tab insertion and increasing assembly complexity, especially with multiple units.
Innovation Solution
A busbar assembly design featuring a busbar bracket with alternately distributed notches that guide tab insertion, allowing for clear visualization and real-time adjustment during assembly, along with snap-fit and hot-melt connections for secure electrical connections between busbar bodies and the bracket.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the busbar assembly uses a solid busbar bracket without notches, then the structural integrity is maintained, but the line of sight is obstructed and assembly difficulty increases
Solution Approach 1:
The busbar bracket is segmented with multiple notches cut into its surface, dividing the solid structure into sections that provide visual access to the tab insertion points. These notches allow assemblers to see through the bracket and confirm proper tab alignment without moving components, resolving the contradiction between maintaining structural integrity and improving assembly ease.
2Difficulty of detecting and measuring
If the busbar bracket is made more transparent or open, then the line of sight improves, but the structural strength and stability decrease
Solution Approach 1:
Rather than making the entire bracket transparent or open which would compromise strength, the design segments the bracket surface with localized notches. These notches provide sufficient visual access for detecting tab insertion while maintaining the overall solid structure and mechanical strength of the busbar bracket.
Solution Approach 2:
The bracket maintains solid, strong construction overall but introduces localized notches at specific positions where visual access is needed. This local modification provides the necessary visibility for assembly detection without compromising the global structural strength and stability of the bracket.
Data Source
AI summary
The present application discloses a busbar assembly, a battery and an electrical apparatus. The busbar assembly comprises a busbar bracket and a busbar. The busbar bracket is provided with a plurality of abutting portions and a plurality of first notches alternately distributed along a preset direction, each of the first notches being used for insertion of a tab of a battery cell assembly. The busbar is connected to at least part of the abutting portions and used for electrical connection with tabs inserted into the first notches. The busbar assembly can reduce the difficulty when assembling with the battery cell assembly.