Sliding Bus Bar Holder for Battery Module Tolerance
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Solution Overview
Problem
The challenge in electric-powered vehicles is the time-consuming battery recharging process, which hinders their commercialization due to the limited electric energy supply, and existing bus bar holders face issues with manufacturing tolerances and volume changes of batteries during charging and discharging, leading to connection problems.
Innovation Solution
A bus bar holder with a plate having openings and settling grooves that allow electrode terminals to slide and accommodate manufacturing tolerances, and elastic members or length adjusters to ensure secure and adaptable connections between battery terminals, enabling efficient electrical connectivity despite volume changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed bus bar holder structure is used to connect electrode terminals, then the connection structure is simple, but it cannot accommodate manufacturing tolerances and volume changes of batteries during charging and discharging
Solution Approach 1:
The bus bar holder incorporates a sliding mechanism where the bus bar can move linearly within the holder body along a guide groove. This dynamic structure allows the bus bar to adjust its position to accommodate variations in electrode terminal positions caused by manufacturing tolerances and battery volume changes during charging and discharging cycles
Solution Approach 2:
The connection structure is divided into separate functional components: the holder body, the sliding bus bar, and the guide groove. This segmentation allows each component to perform its specific function independently while working together to provide both adaptability and structural integrity
2Reliability
If the bus bar is fixed rigidly to accommodate precise positioning, then positioning precision is high, but it cannot accommodate volume changes of batteries during charging and discharging
Solution Approach 1:
The sliding mechanism transforms the rigid fixed connection into a dynamic adjustable connection. The bus bar can slide within the holder body to maintain reliable electrical contact even when battery volume changes occur during charging and discharging, while the guide groove ensures the movement remains controlled and precise
3Adaptability or versatility
If the opening length is increased to accommodate larger tolerances, then adaptability to tolerances improves, but the device length increases
Solution Approach 1:
Instead of increasing the length of the bus bar holder, the solution utilizes the linear dimension along the guide groove for the sliding mechanism. This allows the bus bar to move within a controlled path that accommodates tolerance variations without proportionally increasing the overall holder length, as the movement is constrained to a specific directional path
Data Source
AI summary
A bus bar holder for connecting electrode terminals of a plurality of batteries arranged in a lengthwise direction, the bus bar holder including a bus bar holder plate having an opening in a lengthwise direction thereof and configured such that at least some electrode terminals of the plurality of batteries are extendable through the opening and slidable along the opening; and a bus bar for electrically connecting at least two electrode terminals of adjacent batteries, wherein the bus bar holder plate includes a settling groove in which the bus bar is settled, and the bus bar attached to the electrode terminals is slidable when the electrode terminal slides along the opening.