Protruding Busbar Module for Battery Pack Assembly
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Solution Overview
Problem
Conventional busbar modules with planar busbars require extensive time for connection to electrode terminals due to their shape, especially when terminals are at different heights, complicating assembly and increasing the load on the busbar holder.
Innovation Solution
A busbar module design featuring busbars with connection portions that protrude relative to a base portion, allowing for easy and direct connection to electrode terminals, even when they are at different heights, by rotating the busbar to maintain contact without the base portion touching the terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If planar busbars are used to connect electrode terminals, then the busbar structure is simple and easy to manufacture, but it takes much time for workers to weld the connection portions to the electrode terminals when terminals are at different heights
Solution Approach 1:
The busbar connection portion is extended in the height direction (vertical dimension) to create a protruding structure. This dimensional change allows the connection portion to reach electrode terminals at different heights without requiring complex adjustment operations, thereby maintaining manufacturing simplicity while significantly improving assembly speed
Solution Approach 2:
The busbar is pre-formed with connection portions that protrude toward the electrode terminals during the manufacturing process. This preliminary shaping ensures that when assembly occurs, the connection portions are already positioned optimally for welding, eliminating the need for time-consuming manual adjustment during assembly
2Ease of manufacture
If planar busbars are used with electrode terminals at different heights, then the busbar holder must support the entire busbar structure, but this increases the load on the busbar holder
Solution Approach 1:
The connection portions are extracted as distinct protruding elements from the main busbar body. By separating the connection function into dedicated protruding portions, the busbar holder only needs to support the base portion, significantly reducing the load on the holder while maintaining structural simplicity
Solution Approach 2:
The busbar is segmented into a base portion and protruding connection portions. This segmentation allows the base portion to be supported by the busbar holder while the connection portions extend outward to reach terminals, distributing the structural load more efficiently and reducing the burden on the holder
3Ease of operation
If workers manually adjust planar busbars to connect to electrode terminals at different heights, then connection can be achieved, but it complicates the assembly process and increases assembly time
Solution Approach 1:
The busbar's protruding connection portions are designed to automatically align with and reach the electrode terminals at appropriate heights. This self-aligning feature eliminates the need for workers to manually adjust the busbar position or angle, making the connection process intuitive and straightforward while reducing assembly complexity
Data Source
AI summary
A busbar module and a battery pack include busbars each having connection portions protruding toward electrode terminals relative to a base portion located between the connection portions. In the busbar module, for example, the connection portions each share a boundary with the base portion. The boundary extends in a direction orthogonal to a direction in which the busbars are aligned. The connection portions have a shape in which both edges of the busbars in the alignment direction of the busbars are bent toward the electrode terminals with the boundary is used as a bending origin.