Tiltable Bus Bar Battery Module for Faster Cell Assembly
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Solution Overview
Problem
The existing battery module assembly processes are inefficient, leading to increased production costs and reduced productivity, particularly with the growing demand for high-capacity battery cells.
Innovation Solution
A battery module design featuring a base frame, cover frame, and a tiltable bus bar unit with a tension stopper and guide projections to facilitate precise positioning and secure connection of battery cells, enhancing assembly efficiency by preventing component interference and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a plurality of battery cells are connected in series or parallel to configure a battery pack, then the output voltage and charge/discharge capacity can be adjusted to meet various requirements, but the assembling process becomes more complex and less efficient
Solution Approach 1:
The battery pack is divided into multiple battery modules, each containing a specific number of battery cells connected in series. This modular structure allows flexible configuration of output voltage and capacity by assembling different numbers of modules in parallel, while maintaining efficient assembly processes through standardized module units.
Solution Approach 2:
The bus bar unit is designed with universal applicability to connect multiple battery cells and modules. The tiltable structure with guide projections and fixing hooks provides a standardized connection interface that can be used across different module configurations, simplifying the assembling process while supporting various output requirements.
2Device complexity
If traditional fixed bus bar connections are used, then the structure is simple, but component interference and damage risk increase during assembly
Solution Approach 1:
The bus bar unit incorporates a tiltable structure that transitions from a horizontal transport position to a vertical installation position. This dynamic design allows the bus bar to be easily positioned and aligned during assembly, reducing the risk of component interference and damage while maintaining structural integrity through the fixing hooks.
3Manufacturing precision
If precise positioning mechanisms are added to prevent component interference, then assembly accuracy improves, but device complexity increases
Solution Approach 1:
The bus bar unit incorporates guide projections that automatically align with guide grooves on the battery cells during the tilting and installation process. This self-aligning mechanism ensures precise positioning without requiring additional external positioning devices or complex adjustment mechanisms, maintaining simplicity while achieving high assembly accuracy.
Data Source
AI summary
A battery module includes a plurality of battery cells, a base frame configured to support the plurality of battery cells, a cover frame coupled to the base frame to cover the plurality of battery cells, and a bus bar unit coupled to the cover frame in a tiltable manner so as to be pivotable between a first location fixed to the cover frame and a second location fixed to the base frame, where the first location is oriented at a predetermined angle relative to the second location.