Battery Module Cover-Substrate Layout Without Terminal Blocks
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Solution Overview
Problem
Existing battery assemblies face issues with structural instability due to outwardly protruding bus bar terminal blocks, which increase production costs and are prone to shape changes under impact, posing safety risks.
Innovation Solution
A battery assembly design featuring a cover portion with protrusion members that connect to a substrate portion through overlapping regions, through-holes, and pad regions, eliminating the need for separate terminal blocks, thereby enhancing structural stability and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a separate bus bar terminal block protruding outward is applied to the substrate part, then workability in fastening process is improved, but structural stability deteriorates due to shape changes under impact
Solution Approach 1:
The patent merges the bus bar terminal block function with the substrate part itself by forming pad regions directly on the substrate part. This eliminates the need for separate protruding terminal blocks while maintaining electrical connection functionality, thereby improving structural stability without sacrificing workability
Solution Approach 2:
The substrate part is designed to serve multiple functions: it acts as both the structural base and the electrical connection component through integrated pad regions. This multi-functionality eliminates the need for separate terminal blocks, resolving the contradiction between ease of operation and structural stability
2Reliability
If a separate bus bar terminal block is applied, then electrical connection is achieved, but production cost increases due to additional raw materials
Solution Approach 1:
The patent combines the electrical connection function into the substrate part by forming pad regions directly on it. This integration eliminates the need for separate terminal block components, reducing raw material usage and production costs while maintaining reliable electrical connections through the substrate's own conductive regions
3Ease of operation
If protruding bus bar terminal blocks are used, then fastening process is simplified, but safety risk increases due to shape changes under impact
Solution Approach 1:
The patent integrates the terminal block function into the substrate part, eliminating protruding components that could change shape under impact. The pad regions are formed directly on the substrate, maintaining fastening ease while removing the safety hazard of protruding elements
Solution Approach 2:
The patent converts the potential harm of separate protruding terminal blocks into a benefit by integrating the electrical connection function directly into the substrate. This eliminates the safety risk of protruding parts while maintaining operational simplicity
Data Source
AI summary
A battery assembly includes a battery module stack in which at least one battery module is stacked and formed, a cover portion coupled to a side of the battery module stack, and a substrate portion coupled to an external surface of the cover portion, wherein the cover portion includes a cover member coupled to the battery module stack, and a protrusion member protruding in an outward direction from the cover member and in contact with an internal surface of the substrate portion, the substrate portion includes an overlapping region which is a region overlapping the protrusion member when viewed in the outward direction, a through-hole passing through the overlapping region in the outward direction is formed in the overlapping region, and a pad region having electrically conductive properties is formed in a region surrounding the through-hole in the substrate portion.