Battery Pack Holder Layout for Lead Plate Alignment and Welding
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Solution Overview
Problem
The alignment of battery cell positions with lead plates in battery packs is often misaligned, complicating the welding process, especially with increasing numbers of cells and lead plates, leading to inefficiencies in manufacturing.
Innovation Solution
A battery pack design featuring a holder with resin-embedded lead plates and through holes for easy alignment, allowing for insert molding and simplified manufacturing processes, including punch separation to optimize lead plate and signal line positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of battery cells and lead plates is increased to meet higher energy requirements, then the energy capacity of the battery pack is improved, but the alignment complexity between battery cells and lead plates increases, making the welding process more difficult
Solution Approach 1:
The patent introduces a holder as an intermediary component that integrates multiple lead plates and positioning features. The holder serves as a mediator between the battery cells and individual lead plates, pre-establishing the spatial relationships and alignment for all connections. This allows multiple battery cells to be connected systematically through the holder rather than requiring complex direct alignment between each cell and lead plate pair.
2Ease of operation
If traditional separate positioning methods are used for lead plates and battery cells, then manufacturing flexibility is maintained, but the welding process becomes inefficient due to misalignment
Solution Approach 1:
The patent merges the positioning function and the electrical connection function into a single integrated holder component. The holder combines multiple lead plates with built-in positioning structures that directly guide battery cell placement. This integration ensures that alignment precision and welding efficiency are achieved simultaneously, as the positioning and electrical connection are accomplished in one unified structure rather than through separate operations.
3Ease of manufacture
If multiple separate components are used for positioning and connecting lead plates, then design flexibility is improved, but the number of parts and presswork requirements increases
Solution Approach 1:
The holder is designed as a universal component that performs multiple functions simultaneously: it holds and positions multiple lead plates, provides alignment features for battery cells, and establishes electrical connections. This multi-functionality eliminates the need for separate positioning fixtures, clamps, and connection components, thereby reducing the total part count and simplifying the manufacturing process while maintaining design flexibility.
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 design simplifies manufacturing by reducing presswork and part count, facilitating smooth welding operations and optimizing electrical connections, thereby enhancing assembly efficiency.
Implementation Method 1
a first holder disposed on the first side of the plurality of battery cells, the first holder including a resin portion molded from resin and a plurality of lead plates held by the resin portion
Data Source
AI summary
A battery pack includes a left holder. The left holder includes a resin portion molded from resin and a plurality of lead plates held by the resin portion. The plurality of lead plates includes a first lead plate connected to a terminal of a first battery cell and a second lead plate connected to a terminal of another battery cell. In the resin portion, a through hole penetrating the resin portion in a left-right direction is formed. The through hole is located between outer edges of the two lead plates.