Battery Assembly Module Caulking Pipe Pressing Mechanism
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Solution Overview
Problem
Conventional voltage sensing methods for high voltage battery cells in electric vehicles face challenges such as quality defects, complexity in triple welding, and vulnerability to vibration, leading to increased manufacturing costs and reduced assembly reliability.
Innovation Solution
A battery assembly module design that eliminates welding by using a caulking pipe to securely connect pouch cells and voltage sensing busbars through a pressing mechanism, reducing the number of manufacturing processes and improving assembly stability under vibration conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If triple welding is used to connect voltage sensing busbars to cell tabs, then electrical connection is achieved, but manufacturing complexity and quality defects increase
Solution Approach 1:
The patent extracts the welding process from the connection method and replaces it with a mechanical pressing structure. The voltage sensing busbar is connected to cell tabs through a pressing mechanism rather than welding, eliminating the complex triple welding process while maintaining electrical connection reliability.
Solution Approach 2:
The patent replaces the welding mechanism (thermal/chemical bonding) with a mechanical pressing system. The pressing structure applies mechanical force to establish electrical contact between the voltage sensing busbar and cell tabs, substituting the welding process with a purely mechanical connection method.
2Reliability
If triple welding is used to connect voltage sensing busbars, then electrical connection is established, but manufacturing time and cost increase
Solution Approach 1:
The patent removes the time-consuming welding process from the manufacturing sequence and replaces it with a rapid mechanical pressing operation. This extraction of the welding step significantly reduces manufacturing cycle time while maintaining connection stability through the pressing mechanism.
Solution Approach 2:
The patent skips the lengthy welding process entirely and rushes through the connection step using a quick pressing action. The mechanical pressing can be performed rapidly without the need for heating, cooling, or quality inspection associated with welding, thereby improving manufacturing efficiency.
3Ease of manufacture
If receptacle type voltage sensing busbar is used, then assembly is simplified, but vibration resistance decreases
Solution Approach 1:
The patent employs a curved or bent pressing structure that applies distributed pressure across the contact interface between the voltage sensing busbar and cell tabs. This curved pressing mechanism enhances contact stability and vibration resistance while maintaining ease of assembly through the modular pressing structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances quality, reduces manufacturing costs, and stabilizes voltage sensing under impact conditions by using a pressing force to firmly connect cell tabs with voltage sensing busbars, eliminating the need for welding and improving assembly efficiency.
Implementation Method 1
stabilizes voltage sensing under impact conditions by using a pressing force to firmly connect cell tabs with voltage sensing busbars
Data Source
AI summary
A battery assembly module according to one embodiment of the present invention includes an upper cover having coupling holes formed at a plurality of locations therein, a lower cover disposed to correspond to the upper cover and having coupling holes formed at a plurality of locations therein, a plurality of pouch cells to which electrodes are connected to one side and the other side thereof and which store or supply electricity, a plurality of cartridges stacked and accommodating the plurality of pouch cells, and a plurality of caulking pipes fixedly coupling the plurality of cartridges accommodating the pouch cells between the upper cover and the lower cover.