Elastic Bus Bar Assembly for Battery Lead Misalignment and Swelling
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Solution Overview
Problem
Conventional battery modules suffer from welding defects due to protruding steps or misalignment between electrode leads and sensing bus bars, leading to electrode damage and degraded welding quality, and are prone to damage during cell swelling.
Innovation Solution
A battery module design featuring a bus bar assembly with elastic guiders that allow the sensing bus bar to move elastically, correcting misalignments and protrusions, and an anti-separation stopper to prevent separation, ensuring accurate welding and minimizing electrode lead damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the sensing bus bar is fixed to the bus bar frame in a conventional battery module, then the assembly structure is simple and stable, but the electrode lead is intensively pressed and damaged when correcting protruding step or misalignment
Solution Approach 1:
The sensing bus bar is designed to be movable rather than fixed, allowing it to move in the left-right direction to correct misalignment and protruding steps. The elastic guider provides dynamic adjustment capability while the sensing bus bar remains connected to the battery cell, resolving the contradiction between alignment correction and electrode lead protection.
Solution Approach 2:
The position of the sensing bus bar is changed from a fixed state to a movable state with elastic guidance. This parameter change allows the sensing bus bar to adjust its position to accommodate assembly tolerances without intensively pressing the electrode lead, thereby preventing damage.
2Manufacturing precision
If pressing jig is used to correct protruding step or misalignment in conventional battery module, then welding quality can be improved, but the flexible electrode lead is damaged due to intensive pressing
Solution Approach 1:
Instead of using a pressing jig that applies intensive force, the invention uses a movable sensing bus bar with elastic guidance. The sensing bus bar naturally moves to the correct position through elastic guidance, achieving welding quality improvement without intensive pressing that would damage the electrode lead.
Solution Approach 2:
The elastic guider acts as an intermediary between the fixed bus bar frame and the movable sensing bus bar. It provides the necessary guidance and elastic support to enable the sensing bus bar to move to the correct position without requiring intensive pressing, thereby preventing electrode lead damage while ensuring welding quality.
3Strength
If the sensing bus bar is made movable to correct misalignment, then electrode lead damage is prevented, but the assembly structure becomes more complex
Solution Approach 1:
The elastic guider serves as a simple intermediary component that enables the sensing bus bar to move while maintaining connection to the bus bar frame. This straightforward mechanism adds minimal structural complexity while effectively preventing electrode lead damage through movable alignment correction.
Solution Approach 2:
The elastic guider can be implemented as a flexible component (such as a spring or elastic element) that provides the necessary movement capability in a compact and simple manner. This flexible approach allows the sensing bus bar to move for alignment correction without significantly increasing the overall structural complexity of the bus bar assembly.
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
Prevents electrode lead damage and maintains welding quality by correcting misalignments and protrusions, and mitigates damage during cell swelling through elastic support, enhancing the reliability of the battery module and pack.
Implementation Method 1
at least one elastic guider configured to elastically support the at least one sensing bus bar
Implementation Method 2
accommodating cell swelling through adjustable positioning
Data Source
AI summary
A battery module according to an embodiment of the present disclosure includes a plurality of battery cells and a bus bar assembly configured to electrically connect the electrode leads of the battery cells, and the bus bar assembly includes a bus bar frame configured to cover one side of the battery cells, a plurality of lead slots through which the electrode leads pass, a sensing bus bar connected to the electrode leads, and an elastic guider disposed at both left and right sides and a rear side of the sensing bus bar in a left and right direction and a front and rear direction of the bus bar frame.