Battery Module Busbar Overmolding Integration
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Solution Overview
Problem
The existing battery module assembly methods are costly, time-consuming, and prone to errors due to manual mounting of busbars, which can lead to improper positioning and increased risk of damage during the assembly process.
Innovation Solution
A battery module design featuring a U-shaped busbar with isosceles trapezoidal seating parts and overmolding integration with a holder, reducing material usage and stress concentration, and allowing for easy and precise assembly through an overmolding process without adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual mounting methods are used for busbars, then assembly flexibility is maintained, but assembly cost increases and assembly time is consumed
Solution Approach 1:
The busbar is divided into distinct functional segments: a seating part that interfaces with the holder and a connection part that connects to battery terminals. This segmentation allows the busbar to be precisely positioned and secured through the overmolding process, eliminating manual assembly steps while maintaining assembly flexibility.
Solution Approach 2:
The holder is pre-designed with an integrated overmolding structure that includes positioning features and securing mechanisms. This preliminary design enables the busbar to be automatically positioned and fixed during the overmolding process, reducing assembly time and cost while eliminating manual intervention.
2Manufacturing precision
If manual mounting methods are used for busbars, then positioning adjustments are possible, but positioning precision decreases and error risk increases
Solution Approach 1:
The busbar features a specifically designed seating part with geometric characteristics (such as an isosceles trapezoidal cross-section) that provide precise positioning when engaged with the holder's overmolding structure. This localized geometric design ensures accurate positioning without requiring manual adjustment, thereby improving positioning precision and reducing error risk.
Solution Approach 2:
The overmolding structure incorporates self-positioning features that guide the busbar into the correct position during assembly. The geometric interlocking between the seating part and the holder's overmolding ensures automatic alignment, eliminating the need for manual positioning adjustments and reducing positioning errors.
3Strength
If traditional busbar structures are used, then material usage is sufficient, but structural integrity decreases and stress concentration increases
Solution Approach 1:
The busbar connection part features a curved stress relaxation portion that transitions between the seating part and the connection part. This curved geometry distributes mechanical stresses more evenly, reducing stress concentration points and enhancing structural integrity. The curved design also optimizes material distribution, maintaining strength while potentially reducing overall material usage.
4Reliability
If busbars are mounted using existing methods, then assembly is possible, but risk of damage during assembly increases
Solution Approach 1:
The overmolding structure is designed to provide protective cushioning during the assembly process. The molded material envelops the busbar seating part, distributing assembly forces evenly and preventing localized stress concentrations that could cause damage. This pre-designed protective structure reduces the risk of damage during assembly while maintaining manufacturing simplicity.
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
The solution simplifies and cost-reduces the assembly process, enhances the structural integrity of the busbar, and ensures precise positioning, thereby improving manufacturing efficiency and reducing the risk of damage during battery cell expansion.
Implementation Method 1
a fixing part covering at least a portion of an edge of the seating part, the fixing part being integrated with the holder
Implementation Method 2
a stress relaxation part that is cut at a predetermined curvature radius inward from an edge thereof may be provided between the seating part and the connection part
Data Source
AI summary
A battery module includes a battery cell including an electrode terminal, a holder adjacent to the battery cell, the holder having an opening at a position corresponding to the electrode terminal, at least one busbar including a seating part and a connection part extending from the seating part, the seating part being positioned on the holder, and the connection part being electrically connected to the electrode terminal through the opening of the holder, and a fixing part covering at least a portion of an edge of the seating part, the fixing part being integrated with the holder.