Battery Pack Holder Welding Part for Bus Bar Connection
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Solution Overview
Problem
The manufacturing process for battery packs with multiple cells is complex and costly, requiring efficient methods to combine bus bars with electrode tabs while minimizing size and optimizing assembly.
Innovation Solution
A battery pack design featuring a battery holder with a welding part that contacts the electrode tab, allowing for laser welding of the bus bar with the welding part through an interposed electrode tab, simplifying the manufacturing process and reducing costs by eliminating the need for additional coupling units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional manufacturing process with separate coupling units is used to combine bus bars with electrode tabs, then the connection reliability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The welding part is integrated directly into the battery holder structure, merging the functions of the battery holder and the coupling unit into a single component. This eliminates the need for separate coupling units while maintaining the electrical connection function, thereby reducing device complexity and manufacturing cost without compromising connection reliability
Solution Approach 2:
The battery holder is designed to serve multiple functions: it holds the battery cells in place and simultaneously provides the welding part for electrical connection. This multi-functional design reduces the number of components needed and simplifies the manufacturing process while ensuring reliable electrical connections
2Strength
If additional coupling units are used to connect bus bars with electrode tabs, then the connection strength is improved, but the battery pack volume increases
Solution Approach 1:
The welding part is formed as an integral part of the battery holder, eliminating the need for separate coupling units. This merging of functions reduces the overall volume required for connections while maintaining adequate connection strength through direct welding
3Manufacturing precision
If a multi-step assembly process is used to combine bus bars with electrode tabs, then the manufacturing precision is improved, but the productivity decreases
Solution Approach 1:
The welding part is pre-formed as an integral part of the battery holder during holder manufacturing. This preliminary action eliminates the need for separate assembly steps to install coupling units, reducing the number of manufacturing steps while maintaining precision through integrated design
Solution Approach 2:
The battery holder and welding part are manufactured as a single integrated component, combining multiple manufacturing operations into one process. This reduces the total number of assembly steps required and improves productivity without sacrificing manufacturing precision
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 enables a compact, high-capacity battery pack with reduced manufacturing costs and simplified assembly, facilitating efficient electrical connections between unit cells.
Implementation Method 1
the bus bar is combined with the welding part via a welding process while the electrode tab is interposed between the bus bar and the welding part
Implementation Method 2
a welding part that contacts the electrode tab
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Provided is a battery pack (100) including a plurality of unit cells (110); a battery holder(120) in which the plurality of unit cells are mounted; an electrode tab (130) arranged on the battery holder; and a bus bar (140) of which portion is arranged on the electrode tab, wherein the battery holder includes a welding part (124, 126) that contacts the electrode tab.