Uniform Insulating Cover Busbar Module for Battery Assembly
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Solution Overview
Problem
Conventional power-supply units for electric and hybrid vehicles require complex assembly of multiple connecting members to connect batteries in series, leading to increased cost and complexity due to the need for different dies and hinges to accommodate varying electrode configurations.
Innovation Solution
A bus bar module with a plate and insulating covers of uniform shape and size, featuring slits, positioning holes, and engaging mechanisms that allow for flexible alignment and assembly with a single die, reducing production costs and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate insulating covers are used for first and second receiving portions, then the battery assembly can be connected in series with proper insulation, but the device complexity increases due to requiring different dies and multiple components
Solution Approach 1:
The patent combines the first insulating cover and second insulating cover into a single integrated insulating cover that covers both the first receiving portion and second receiving portion. This merging reduces the number of separate components from two to one, simplifying the overall structure while maintaining the necessary insulation functionality for series-connected batteries.
Solution Approach 2:
The integrated insulating cover serves multiple functions simultaneously: it provides insulation for the first receiving portion, insulation for the second receiving portion, and structural support for both bus bar connections. This multi-functional design eliminates the need for separate dedicated covers for each receiving portion.
2Ease of manufacture
If uniform insulating covers are used for all receiving portions, then the manufacturing cost decreases with a single die, but the manufacturing precision must accommodate varying electrode configurations
Solution Approach 1:
The insulating cover incorporates a flexible portion that can dynamically adjust its shape and position to accommodate variations in electrode configurations and assembly tolerances. This flexibility allows the single uniform cover to adapt to different battery arrangements without requiring precise pre-positioning or multiple specialized covers.
Solution Approach 2:
The insulating cover design includes variable thickness regions and flexible portions that change physical parameters (rigidity, shape) to accommodate different electrode positions. The flexible portion can deform within certain limits to compensate for manufacturing tolerances in battery electrode positioning.
3Reliability
If multiple separate connecting members are assembled, then the batteries can be connected in series with proper electrode alignment, but the assembly working becomes complex
Solution Approach 1:
The patent merges multiple separate connecting members (first insulating cover, second insulating cover, first bus bar, second bus bar) into an integrated bus bar module where all components are pre-assembled and interconnected. This single modular unit replaces multiple separate assembly operations, simplifying the connection process while ensuring proper electrode alignment through the integrated design.
Data Source
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AI summary
A power-supply unit and a bus bar module which can reduce die cost of an insulating cover are provided. Each of the two insulating covers is provided so as to cover both a first receiving portion and a second receiving portion. For this reason, the two insulating covers arranged on a plate and aligned in an overlapping direction of a battery can be formed in the same shape and same size.