Oblique Bus Bar Battery Module Assembly
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Solution Overview
Problem
The existing battery module assembly process is complicated due to the need for varying lengths of connecting terminals to connect bus bars and sampling circuits, increasing manufacturing difficulty.
Innovation Solution
A battery module design featuring obliquely disposed bus bars and standardized connecting terminals with a flexible flat cable, where each connecting terminal has a first portion connected to a bus bar and a second portion connected to the cable, simplifying the assembly process by using a single specification for connecting terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If connecting terminals with different lengths are designed to connect bus bars and sampling circuit according to battery arrangement, then the battery module can be assembled, but the manufacturing difficulty increases
Solution Approach 1:
The connecting terminal is designed with a universal structure that can connect to bus bars at different positions through flexible positioning. The terminal includes a first connecting portion for the bus bar and a second connecting portion for the sampling circuit, with an insulating structure that allows adaptation to different battery arrangements without requiring different terminal lengths, thus achieving multi-functionality with a single terminal design.
Solution Approach 2:
The connecting terminal is divided into distinct functional segments: a first connecting portion for the bus bar, a second connecting portion for the sampling circuit, and an insulating structure. This segmentation allows each part to be optimized independently while maintaining overall simplicity, enabling the same terminal design to work with various battery configurations.
2Ease of manufacture
If bus bars are arranged in traditional straight configuration, then the structure is simple, but the battery arrangement difficulty increases
Solution Approach 1:
The bus bar is designed with an oblique arrangement instead of traditional straight horizontal or vertical configuration. By introducing a diagonal dimension, the bus bar can better accommodate the spatial arrangement of batteries, reducing arrangement difficulty while maintaining structural simplicity. The insulating structure on the bus bar further facilitates this oblique positioning.
Data Source
AI summary
A battery module includes batteries, bus bars, a flexible flat cable and connecting terminals. Each battery includes a first electrode and a second electrode. Each bus bar connects the first electrode of one battery with the second electrode of another battery. At least one of the bus bar is arranged obliquely. The flexible flat cable includes a number of wires arranged in parallel. Each connecting terminal includes a first connecting portion connected to a corresponding bus bar and a second connecting portion connected to a corresponding wire of the flexible flat cable. Compared with the prior art, at least one of the bus bars of the present disclosure is arranged obliquely, thereby reducing the difficulty of arranging the batteries. In addition, by providing the first connecting portion and the second connecting portion, it is convenient to realize the assembly of the battery module.