Battery Cell Connector Assembly for Tolerance-Absorbing Replacement
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Solution Overview
Problem
Conventional battery pack assembly methods, which rely on welding, result in high repair costs due to the inability to replace individual cells without damaging others, and pose a risk of short-circuiting from cell size tolerance issues and pre-tightening force application.
Innovation Solution
A battery component and assembly process featuring a box body with movably assembled electrical connectors and coolant pipes, allowing for detachable cell insertion/removal, elastic adjustments, and spring-supported tolerances to absorb cell size variations, enabling easy maintenance and reduced risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to connect cells to electrical connectors, then electrical connection reliability is improved, but repairability deteriorates and repair costs increase
Solution Approach 1:
The electrical connection system is segmented into modular components: electrical connectors with contact pieces, terminal pieces, and insulation pieces that can be independently assembled and disassembled. This segmentation allows individual cells to be replaced without affecting the entire electrical connection system, resolving the contradiction between connection reliability and repairability.
Solution Approach 2:
The electrical connector incorporates elastic contact pieces that can dynamically adjust their position and contact force. This dynamic capability allows the connector to accommodate cell size variations while maintaining reliable electrical contact, and enables easy disassembly for cell replacement without damaging the connection system.
2Stability of the object's composition
If fixed cell tabs are used for pre-tightening force application, then structural stability is improved, but cell damage risk increases due to tab stretching
Solution Approach 1:
The electrical connector uses flexible insulation pieces and elastic contact pieces that can deform elastically under pre-tightening force. This flexibility allows the connector to absorb mechanical stress without transmitting excessive force to the cell tabs, preventing tab stretching and cell damage while maintaining structural stability.
Solution Approach 2:
The elastic contact pieces are designed to provide cushioning force before the pre-tightening force is fully applied. This beforehand cushioning protects the cell tabs from sudden stress shocks during the tightening process, reducing the risk of cell damage while ensuring stable connection.
3Force
If thin cell tabs are used to connect to metal busbar portions, then pre-tightening force absorption is improved, but manufacturing precision requirements increase
Solution Approach 1:
The electrical connector serves as an intermediary component between the cell tabs and the electrical connection system. It includes insulation pieces that wrap around the tabs and contact pieces that provide electrical connection, thereby mediating the connection and reducing the precision requirements for direct tab-to-busbar alignment while maintaining force absorption capability.
Solution Approach 2:
The electrical connector changes the mechanical parameters of the connection system by introducing elastic deformation capability through its flexible insulation pieces and elastic contact pieces. This parameter change allows for greater tolerance in tab dimensions and positioning while maintaining effective force absorption and electrical connection.
4Ease of manufacture
If cell size tolerance is not controlled, then ease of manufacture is improved, but short-circuit risk increases due to tab connection
Solution Approach 1:
The electrical connector acts as an intermediary that isolates the electrical connection path from direct tab-to-tab contact. The insulation pieces prevent unintended electrical contact between adjacent cells even when tabs are in close proximity due to size tolerance variations, thereby eliminating short-circuit risk while maintaining ease of manufacture.
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 solution reduces repair costs, improves maintenance efficiency, and minimizes cell damage by allowing single-cell replacement and absorption of size deviations, while maintaining structural stability and heat dissipation capabilities.
Implementation Method 1
spring-supported tolerances to absorb cell size variations
Data Source
AI summary
The present invention relates to a battery component and an assembly process thereof. The battery component includes a box body, cells, electrical connection side plates, and electrical connectors. The electrical connection side plate is installed on an inner sidewall of the box body, the electrical connector is movably assembled on the electrical connection side plate with a plurality of degrees of freedom, and an insertion/removal channel is disposed on the electrical connector. The cell is detachably disposed inside the box body, and a pole of the cell is plug-connected to the insertion/removal channel. In the present invention, repair costs are reduced, maintenance efficiency is improved, and a cell-to-module or cell-to-pack tolerance is absorbed.