Expandable Busbar Case Assembly for Cell Length Variation

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Solution Overview

Problem

In energy storage modules, variations in the total length of cells or busbar case dimensions from design specifications can make it difficult to engage end plates with the busbar case during manufacturing.

Innovation Solution

The busbar case is designed with expandable portions, such as hinges or flat springs, allowing it to adjust to varying cell lengths, and includes a central case with protruding portions for easier alignment and engagement with end plates.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the busbar case is made with fixed rigid structure, then manufacturing precision is improved, but adaptability to varying cell lengths deteriorates

Engineering Contradiction:

Improvebusbar case dimension precisionVSAvoidadaptability to cell length variation

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The busbar case is divided into multiple segments (first busbar case, second busbar case, third busbar case) that can move relative to each other along the first direction. This segmentation allows the overall structure to adapt to varying cell lengths while maintaining precise dimensions for each individual segment, resolving the contradiction between manufacturing precision and adaptability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The busbar case transitions from a fixed rigid structure to a dynamic structure with movable segments connected by connection portions. These connection portions enable the busbar case to adjust its total length dynamically to match variations in cell assembly length, while each segment maintains its manufactured precision.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If the busbar case is made with adjustable structure, then adaptability to varying cell lengths is improved, but device complexity increases

Engineering Contradiction:

Improveadaptability to cell length variationVSAvoidbusbar case structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The busbar case is segmented into multiple cases connected by simple connection portions, allowing adaptability through relative movement rather than complex mechanisms. Each segment remains structurally simple, and the connection portions use straightforward engagement features, maintaining overall structural simplicity while achieving adaptability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connection portions between busbar case segments provide flexible connection that allows relative movement in the first direction. This flexibility is achieved through simple structural features rather than complex mechanisms, enabling the busbar case to adapt to length variations without significantly increasing device complexity.

Inventive Principle:

Principle #30Flexible shells and thin films

3Manufacturing precision

If the end plates are engaged with fixed busbar case, then manufacturing precision is improved, but ease of manufacture deteriorates

Engineering Contradiction:

Improveengagement position precisionVSAvoidengagement process ease

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The busbar case segments can move relative to each other during the engagement process, allowing the end plates to be engaged at precise positions while the segments adjust their positions to accommodate variations in cell assembly length. This dynamic adjustment simplifies the engagement process compared to requiring precise pre-positioning of a fixed structure.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The connection portions are designed with features that enable preliminary positioning and gradual engagement. The segments can initially be positioned loosely and then adjusted to their final precise positions during assembly, making the manufacturing process easier while maintaining engagement precision.

Inventive Principle:

Principle #10Preliminary action

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

Facilitates easy engagement of the busbar case with end plates even when cell lengths deviate significantly from design dimensions, ensuring secure and stable assembly.

Implementation Method 1

The first expandable portion is expandable in the first direction... even when the total length of the cells in the first direction varies relatively significantly from the design dimension, the busbar case can be easily engaged with the first end plate and the second end plate by expanding the first expandable portion

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

the first expandable portion may be a hinge or a member in a shape of a flat spring... the first expandable portion is expandable in the first direction

Methodology Applied

Scientific EffectSpring: Spring

Data Source

PatentUS12456783B2Energy storage module

Publication Date: 2025.10.28 TOYOTA JIDOSHA KK

AI summary

An energy storage module includes a plurality of cells, a first end plate, a second end plate, and a busbar module. The busbar module includes a plurality of busbars and a busbar case that holds the busbars. The busbar case includes a first end case, a second end case, and a connection portion. The first end case engages with the first end plate. The second end case is located to be separate from the first end case in the first direction, and engages with the second end plate. The connection portion connects the first end case and the second end case to each other. The connection portion includes a first expandable portion that is expandable in the first direction.