Snap-fit E-carrier Bus Bar Assembly for Battery Modules
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Solution Overview
Problem
Traditional battery modules face challenges in easily accessing electrochemical cells for replacement due to difficult removal of bus bars and E-carriers, which are often bolted or welded, and size and shape variations of cells complicating electrical coupling.
Innovation Solution
A snap-fit E-carrier system that removably couples to the battery module housing without bolts or adhesives, using snap-fitting, clasping, friction, or interference fitting, allowing for easy access and standardized dimensions for electrochemical cells, facilitating assembly and reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bus bars and E-carriers are bolted or welded to battery modules, then electrical connection reliability is improved, but ease of repair deteriorates due to difficult removal for cell replacement
Solution Approach 1:
The E-carrier is divided into separate modular components including the E-carrier body, bus bar assembly, and terminal connections. This segmentation allows the bus bar assembly to be independently removed from the E-carrier body, enabling cell replacement without removing the entire E-carrier or bus bars, thus maintaining electrical reliability while improving repairability
Solution Approach 2:
The patent introduces a removable and reconfigurable bus bar assembly that can be dynamically detached and reattached to the E-carrier. This dynamic design allows the electrical connection system to transition between fixed (for reliability) and removable (for repair) states, resolving the contradiction between connection stability and maintenance accessibility
2Ease of manufacture
If traditional battery module assembly methods are used, then manufacturing experience is leveraged, but productivity deteriorates due to time-consuming assembly and disassembly operations
Solution Approach 1:
The battery module is segmented into independently replaceable units: the E-carrier body, bus bar assembly, and cell cartridges. This segmentation enables parallel assembly operations and reduces the time required for cell replacement from hours to minutes, significantly improving productivity while maintaining manufacturing simplicity
Solution Approach 2:
The bus bar assembly is pre-configured with connection terminals and electrical contacts before being attached to the E-carrier. This preliminary preparation allows for rapid assembly and disassembly operations during maintenance, eliminating the need for complex on-site electrical connections and improving overall assembly efficiency
3Reliability
If bus bars are permanently fixed to E-carrier, then electrical connection stability is improved, but ease of manufacture deteriorates due to complex welding or bolting processes
Solution Approach 1:
The patent replaces traditional mechanical fastening methods (welding or bolting) with a simplified mechanical insertion system. The bus bar assembly features guide rails and engagement features that allow it to be securely attached to the E-carrier body through simple insertion and latching operations, eliminating complex welding or bolting processes while maintaining connection stability
Solution Approach 2:
The E-carrier body serves as an intermediary component between the battery cells and the bus bar assembly. It provides a standardized interface with guide rails and engagement features that simplify the connection process, reducing manufacturing complexity while ensuring stable electrical connections through precise mechanical alignment
Data Source
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AI summary
A battery module includes a housing having an opening and a plurality of electrochemical cells disposed in the housing. The plurality of electrochemical cells have electrode terminals. The battery module also includes a carrier defined by an outside boundary and coupled to the plurality of electrochemical cells. The outside boundary of the carrier and the housing are in a nested arrangement. The battery module also includes a bus bar assembly disposed on the carrier, the bus bar assembly includes bus bars that electrically couple the electrode terminal of one of the plurality of electrochemical cells to a respective electrode terminal of another one of the plurality of electrochemical cells.