Insert-Injection Molded Busbar Assembly for Battery Modules

Solution Overview

Problem

Existing battery modules face issues with the busbar and busbar frame not being securely coupled due to assembly tolerance, leading to potential swaying or loosening of the busbar assembly, which can affect electrical connections, especially under vibrations in applications like vehicles.

Innovation Solution

The integration of busbars and busbar frames through insert-injection molding, where the busbar is made of metal and the frame of insulating plastic, with features like through holes and depressed portions to secure the busbar assembly, ensuring a tight and stable connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If thermal bonding is used to assemble and fix the busbar to the busbar frame, then the assembly process is simple, but the busbar may deviate due to assembly tolerance and there may be a lack of close-contact force

Engineering Contradiction:

Improveassembly process simplicityVSAvoidbusbar positioning accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The busbar and busbar frame are merged into a single integrated component through insert injection molding. The metal busbar is inserted into the mold cavity, and plastic material is injected to form the busbar frame that tightly surrounds and bonds to the busbar, eliminating the need for separate assembly steps and achieving precise positioning without deviation

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention uses composite materials by combining metal (busbar) and plastic (busbar frame) through insert injection molding. The plastic material flows around and bonds to the metal busbar, creating a strong, precise, and integrated assembly that eliminates positioning tolerance issues while maintaining manufacturing efficiency

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If thermal bonding is used to assemble and fix the busbar to the busbar frame, then the assembly process is simple, but there may be a lack of close-contact force leading to loosening

Engineering Contradiction:

Improveassembly process simplicityVSAvoidcoupling force between busbar and busbar frame

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The busbar and busbar frame are merged into a single integrated component through insert injection molding. The metal busbar is inserted into the mold cavity, and plastic material is injected to form the busbar frame that tightly surrounds and bonds to the busbar, eliminating the need for separate assembly steps and achieving precise positioning without deviation

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention uses composite materials by combining metal (busbar) and plastic (busbar frame) through insert injection molding. The plastic material flows around and bonds to the metal busbar, creating a strong, precise, and integrated assembly that eliminates positioning tolerance issues while maintaining manufacturing efficiency

Inventive Principle:

Principle #40Composite materials

3Device complexity

If the busbar assembly is not securely coupled, then the structure is simpler to manufacture, but the electrical connections may be affected under vibrations

Engineering Contradiction:

Improvebusbar assembly structure complexityVSAvoidelectrical connection stability under vibration

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The busbar and busbar frame are merged into a single integrated component through insert injection molding. The metal busbar is inserted into the mold cavity, and plastic material is injected to form the busbar frame that tightly surrounds and bonds to the busbar, eliminating the need for separate assembly steps and achieving precise positioning without deviation

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention uses composite materials by combining metal (busbar) and plastic (busbar frame) through insert injection molding. The plastic material flows around and bonds to the metal busbar, creating a strong, precise, and integrated assembly that eliminates positioning tolerance issues while maintaining manufacturing efficiency

Inventive Principle:

Principle #40Composite materials

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 method provides a robust and secure coupling of busbars and busbar frames, preventing swaying and loosening, thus maintaining reliable electrical connections even under mechanical stress, enhancing the structural integrity and performance of battery modules.

Implementation Method 1

a busbar assembly in which a busbar and a busbar frame are integrally formed by insert injection molding

Methodology Applied

Scientific EffectInsert injection molding:

Data Source

PatentUS11349181B2Battery module including insert-injection molded busbar assembly

Publication Date: 2022.05.31 LG ENERGY SOLUTION LTD

AI summary

A battery module includes a cell assembly including at least one battery cell; a module casing configured to accommodate the cell assembly; and a busbar assembly integrated by forming, by insert-injection molding, a busbar electrically connected to an electrode lead of the cell assembly, and a busbar frame configured to cover the cell assembly at least at one side thereof.