Battery Cell Assembly Housing With Integrated Terminals for Mass Production
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Solution Overview
Problem
Current battery cell assembly and pack manufacturing processes face inefficiencies in production and reliability, particularly in mass production and integration into green technology applications like electric vehicles and renewable energy systems.
Innovation Solution
A battery cell assembly design featuring a rigid assembly housing with integrated busbar and terminal units, and a battery pack configuration with ventilation and cooling passages, enhancing manufacturing efficiency and reliability by facilitating direct cell-to-pack integration and improved thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional battery cell assembly processes are used, then manufacturing complexity is high, but manufacturing efficiency is low and mass production is difficult
Solution Approach 1:
The battery pack is divided into multiple battery cell assemblies, each independently structured with its own housing, busbar members, and terminal units. This segmentation allows for standardized mass production of individual assemblies that can be easily combined, thereby improving manufacturing efficiency while reducing overall process complexity
Solution Approach 2:
The busbar members are designed with multi-functional capabilities: they serve as electrical connectors between cells, provide structural support within the assembly housing, and enable modular integration. This universality reduces the number of separate components needed, simplifying manufacturing processes while maintaining high productivity
2Reliability
If battery cells are directly assembled without integrated terminal units, then assembly is simpler, but reliability is reduced
Solution Approach 1:
The terminal units are integrated directly into the assembly housing structure, merging the functions of electrical connection and mechanical support into a single unified component. This integration enhances reliability by reducing connection points and potential failure modes, while the unified structure actually simplifies the overall assembly process
Solution Approach 2:
The busbar members are nested within the assembly housing, with terminal units positioned to extend through the housing walls. This nested arrangement allows for compact, reliable connections while maintaining a clean external appearance and simplified assembly interface
3Ease of operation
If terminal units extend outside the housing, then electrical connection is easier, but manufacturing precision requirements increase
Solution Approach 1:
The terminal units are pre-positioned and fixed to the assembly housing during the manufacturing process, with their locations and orientations predetermined by the housing structure. This preliminary positioning ensures high manufacturing precision is achieved through fixture-based assembly, while the extended terminals remain easily accessible for electrical connections during installation
4Adaptability or versatility
If open slots are formed in the housing, then cell accommodation is improved, but structural strength is reduced
Solution Approach 1:
The assembly housing is designed with open slots at specific locations where cells need to be accommodated, while maintaining full structural integrity in other areas. The housing material and cross-sectional geometry are optimized locally around the slot regions to compensate for the openings, ensuring that structural strength is preserved while achieving the required adaptability for cell installation
Data Source
AI summary
The battery cell assembly includes an assembly housing, and a battery cell, a first busbar member and a second busbar member accommodated in the assembly housing. The first busbar member is connected to a first electrode lead of the battery cell and the second busbar member is connected to a second electrode lead of the battery cell. The battery cell assembly also includes first and second terminal units connected to the first and second busbar members, respectively. At least portions of the first terminal unit and the second terminal unit extend toward a first surface of the assembly housing and disposed outside of the assembly housing. The assembly housing includes an accommodation space in which the battery cell is accommodated and an open slot formed by opening a second surface of the assembly housing to connect the accommodation space to the outside of the accommodation space.