Battery Pack Busbar Holder Assembly for Stable Sensor Welding
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Solution Overview
Problem
Existing rechargeable battery packs face challenges in ensuring stable electrical connections and preventing welding defects when integrating temperature sensors, which can impede the accurate temperature measurement and overall durability of the battery pack.
Innovation Solution
A rechargeable battery pack design featuring a busbar holder with an insertion groove and a fixing portion, along with an attachment plate and temperature sensor, where the attachment plate is securely inserted and fixed to ensure precise positioning and stable electrical connection, allowing for improved welding quality and durable temperature sensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the temperature sensor is directly connected to the busbar holder, then the electrical connection is established, but welding defects occur and connection stability is poor
Solution Approach 1:
The patent introduces an attachment plate as an intermediary component between the temperature sensor and the busbar holder. The attachment plate includes an insertion portion that fits into an insertion groove on the busbar holder and a sensor mounting portion that secures the temperature sensor. This intermediary structure eliminates direct welding between the temperature sensor and busbar holder, preventing welding defects while ensuring stable electrical connection through the conductive attachment plate.
2Reliability
If the attachment plate is securely fixed to the busbar holder, then connection stability is improved, but the positioning precision must be high
Solution Approach 1:
The attachment plate is pre-formed with an insertion portion that has a specific shape (e.g., L-shaped or U-shaped) designed to fit precisely into a corresponding insertion groove on the busbar holder. This preliminary design of the insertion portion-groove interface ensures accurate positioning during assembly, eliminating the need for high-precision positioning operations during the actual assembly process while maintaining stable connection.
Data Source
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AI summary
A rechargeable battery pack, including a plurality of battery cells, a side frame accommodating the plurality of battery cells, a busbar holder covering an upper portion of the side frame, the busbar holder having an insertion groove in an upper surface thereof, the busbar holder including a fixing portion protruding from a first edge of the insertion groove, the busbar holder electrically connecting the plurality of battery cells to each other, an attachment plate inserted into the insertion groove, the attachment plate having a portion of a second edge fixed to the fixing portion, the attachment plate electrically connected to the busbar holder, and a temperature sensor electrically connected to the attachment plate, the temperature sensor measuring a temperature of the battery cell and transmitting the measured temperature to a protection circuit module.