Battery Cell Rail Slot Assembly for Terminal Protection
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Solution Overview
Problem
In battery packs for electrified vehicles, securing and connecting battery cells efficiently while protecting terminals from inadvertent contact and eliminating the need for separate busbars is a challenge.
Innovation Solution
The use of rails received within slots to secure battery cell assemblies, where rail and slot terminals are disposed within protected surfaces, allowing direct electrical contact between cells without external busbars, and the rail and slot configurations can be slidably or snap-fitted to align cells along a longitudinal axis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If separate busbars are used to connect battery cells, then electrical connection is achieved, but device complexity and number of components increase
Solution Approach 1:
The patent merges the mechanical securing function (rail) with the electrical connection function (terminal) into a single integrated component. The rail includes embedded terminals that directly contact terminals on adjacent cells, eliminating the need for separate busbars while maintaining reliable electrical connection throughout the battery array.
Solution Approach 2:
The rail is designed to perform multiple functions simultaneously: it provides mechanical support and positioning for the battery cells while also serving as an electrical conductor through its embedded terminals. This multi-functional design reduces the total number of components needed in the battery assembly.
2Object-affected harmful factors
If terminals are exposed on outer surfaces for connection, then electrical contact is facilitated, but risk of inadvertent contact and safety hazards increases
Solution Approach 1:
The terminals are nested within recesses or cavities in the rail structure, allowing them to be protected from external contact while still enabling electrical connection. The terminal is positioned inside the rail body rather than protruding outward, creating a protected interface that reduces safety hazards.
3Productivity
If multiple separate components (rails, busbars, connectors) are used to secure and connect cells, then functional requirements are met, but manufacturing complexity and assembly time increase
Solution Approach 1:
The patent combines multiple previously separate components into a single integrated rail assembly. The rail includes built-in terminals and positioning features, replacing the need for separate busbars, connectors, and mounting brackets. This reduction in component count directly decreases assembly time and manufacturing complexity.
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 enhances the secure and efficient connection of battery cells within the pack, reduces the risk of terminal contact, eliminates the need for separate busbars, and simplifies assembly by integrating terminal connections within the cell assemblies, thereby improving the overall structural integrity and electrical communication within the battery pack.
Implementation Method 1
the rail terminal of the first cell assembly electrically contacts a slot terminal of the second cell assembly when the rail is received within the slot to communicate electrical current between the first and second cell assemblies
Data Source
AI summary
An exemplary battery assembly includes, among other things, a rail of a first cell assembly received within a slot of a second cell assembly to secure the first and a second cell assemblies relative to each other. A rail terminal is disposed within a rail surface that faces back toward an electrode structure of the first cell assembly. An exemplary battery cell securing method includes, among other things, positioning a rail of a first cell assembly within a slot of a second cell assembly to secure the first and second cell assemblies relative to each other. The rail has a rail surface that faces back toward an electrode structure of the first cell assembly, and a rail terminal disposed within the rail surface.