Split Busbar Bracket Structure for Flexible Battery Module CCS Assembly
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Solution Overview
Problem
The existing CCS assembly process for battery modules is cumbersome, has a long processing cycle, and incurs high processing costs due to the need for different molds and UV glue application.
Innovation Solution
The integrated busbar is designed with a split structure comprising a mounting bracket and an installation bracket, allowing flexible adjustment and replacement of parts, reducing the complexity of installation and lowering replacement costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an integral one-piece tray design is used for the integrated busbar bracket, then the structural strength and stability are improved, but the adaptability to different CCS structures is reduced and replacement costs increase
Solution Approach 1:
The integrated busbar bracket is divided into multiple independent components including mounting brackets, installation brackets, and connection brackets. Each bracket can be independently selected and replaced based on different CCS structure requirements, thereby improving adaptability while maintaining structural integrity through proper connection designs.
2Ease of manufacture
If an integral one-piece tray design is used for the integrated busbar bracket, then the manufacturing simplicity is improved, but the ease of repair and replacement is reduced
Solution Approach 1:
The bracket system is segmented into multiple replaceable components. When damage occurs to a specific part, only the damaged bracket needs to be replaced rather than the entire one-piece structure, significantly reducing repair time and costs while maintaining manufacturing simplicity for each individual component.
3Manufacturing precision
If different molds and UV glue are used for the CCS assembly process, then the manufacturing precision and protection are improved, but the processing complexity and cycle time increase
Solution Approach 1:
The mounting bracket and installation bracket are designed to work together as an integrated system that combines positioning, mounting, and protection functions. This merged design eliminates the need for separate UV glue application steps and multiple molding processes, reducing processing complexity while maintaining assembly precision through precise mechanical配合 between the bracket components.
Data Source
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AI summary
The application provides an integrated busbar, and a bracket of the integrated busbar, and a battery module of the integrated busbar. The integrated busbar includes a bus assembly and an integrated busbar bracket. The bus assembly is configured to be electrically connected to a plurality of battery cells. The integrated busbar bracket includes a mounting bracket and an installation bracket configured as split structures. Two ends of the bus assembly are installed on the mounting bracket. A middle part of the bus assembly is installed on the installation bracket.