Battery Assembly Cover for Busbar-Free Lead Welding
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Solution Overview
Problem
The existing battery assembly process is complex and costly due to the use of busbars for electrical connections, which also limits space and durability, and there is a need for efficient heat dissipation and safety measures to prevent fires.
Innovation Solution
A battery assembly cover that exposes battery cell leads to the outside for direct welding, eliminating the need for busbars, and includes an insulating portion to ensure electrical insulation and stability, allowing for simplified assembly and increased energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If busbars are used to electrically connect battery cells, then electrical connection is achieved, but assembly complexity increases and space is consumed
Solution Approach 1:
The patent extracts and eliminates the busbar component from the battery assembly system. Instead of using separate busbars for electrical connection, the invention directly connects battery cells through their terminals, removing the intermediate connection component and simplifying the overall structure.
Solution Approach 2:
The invention merges the electrical connection function directly into the battery cell assembly structure. By integrating the connection mechanism within the battery pack housing and using the cell terminals themselves as connection points, the system combines multiple functions into a unified structure, eliminating the need for separate busbars.
2Area of stationary object
If busbars are used for electrical connection, then connectivity is established, but additional space is required in the battery assembly
Solution Approach 1:
The busbar component is completely removed from the system. The invention achieves electrical connection without requiring separate conductor bars, thereby freeing up the space that would have been occupied by busbars and their mounting structures within the battery assembly.
Solution Approach 2:
Instead of using external busbars to connect cell terminals, the invention inverts the approach by having the cell terminals directly interface with each other or with collection plates integrated into the housing. This reversal of the connection architecture eliminates the need for intermediate conductors and optimizes space utilization.
3Reliability
If busbars are used to connect battery cells, then electrical connection is provided, but connection durability is reduced
Solution Approach 1:
By removing the busbar component entirely, the invention eliminates the potential failure points associated with busbar connections. The direct terminal-to-terminal or terminal-to-collection-plate connections reduce the number of interfaces and potential connection failures, improving overall system reliability.
Solution Approach 2:
The invention merges the electrical connection function directly into the battery cell assembly, creating a more integrated and robust connection system. This integration reduces the number of separate components and connection points, thereby improving durability by minimizing potential failure interfaces.
4Quantity of substance
If multiple battery cells are assembled in limited space, then energy density increases, but heat dissipation becomes challenging
Solution Approach 1:
The battery pack housing serves multiple functions: it provides structural support, enables electrical connection through integrated collection plates, and acts as a heat dissipation pathway. By making the housing multi-functional, the system can accommodate higher cell density while maintaining effective thermal management through the same structural components.
Solution Approach 2:
The invention merges the electrical collection function and thermal management function into the housing structure. The collection plates integrated into the housing serve both as electrical conductors and as heat sinks, allowing simultaneous optimization of energy density and heat dissipation without requiring separate dedicated components.
Data Source
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AI summary
Presented are a battery assembly cover, a battery assembly, and a vehicle including same, the battery assembly cover comprising: a base which is coupled to an open surface of a battery assembly case to seal the battery assembly case, has a plurality of first holes formed therein, and allows battery cell leads to pass through each of the first holes to expose the battery cell leads to the outside; and an insulation part which is coupled to the base, is positioned between the edge of the first holes of the base and the battery cell leads to insulate the battery cell leads from the base, and has second holes through which the battery cell leads pass.