Battery Insulating Member with Bus Bar Fixing Section
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Solution Overview
Problem
The existing methods for connecting batteries in series or parallel using bus bars often result in welding failures due to position gaps between external terminals and bus bars, leading to unreliable battery packs with a risk of short circuits and increased manufacturing costs.
Innovation Solution
The use of insulating members with bus bar-fixing sections that caulk and fix the external terminals to the battery lid, ensuring precise positioning and stable bonding through welding, thereby preventing welding failures and enhancing the reliability and safety of the battery pack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bus bars are fastened to external terminals with screws, then the connection can be established, but contact resistance changes when vibration or mechanical force is applied
Solution Approach 1:
The connection structure is divided into multiple functional parts: the insulating member with positioning protrusions, the external terminal with positioning grooves, and the bus bar with positioning protrusions. This segmentation allows each component to perform its specific function (insulation, positioning, electrical connection) independently, ensuring stable contact resistance by preventing relative movement between components.
Solution Approach 2:
The insulating member acts as an intermediary between the external terminal and the bus bar. It provides both mechanical support and precise positioning through its protrusions and grooves, while also providing electrical insulation. This intermediary structure ensures that the bus bar maintains accurate positioning relative to the external terminal, preventing contact resistance variations under vibration or mechanical force.
2Ease of manufacture
If holes are made in bus bars for screw fastening, then connection is possible, but welding failures occur due to position gaps between external terminals and bus bars
Solution Approach 1:
The insulating member is pre-assembled with the external terminal, with its positioning protrusions and grooves already in place. This preliminary action ensures that when the bus bar is subsequently attached, it automatically aligns with the correct position, eliminating position gaps that would otherwise require complex tooling to correct during welding or assembly.
Solution Approach 2:
The invention replaces the need for complex mechanical positioning systems and specialized tooling with a simple insulating member that provides inherent mechanical positioning through its molded protrusions and grooves. This substitution eliminates position gaps without requiring additional positioning devices or complex assembly mechanisms.
3Reliability
If screws are used to fasten bus bars, then connection can be made, but the structure becomes complex and tooling costs increase
Solution Approach 1:
The insulating member combines multiple functions into a single component: electrical insulation, mechanical positioning (through protrusions and grooves), and structural support. This merging eliminates the need for separate fastening devices like screws, simplifying the overall structure while maintaining reliable bonding stability through the integrated positioning features.
Solution Approach 2:
The insulating member serves multiple purposes simultaneously: it provides electrical insulation between conductive parts, establishes precise mechanical positioning through its molded features, and provides structural support for the connection assembly. This multi-functionality reduces the total number of components needed while ensuring reliable and stable bonding.
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 approach stabilizes the bonding resistance between external terminals and bus bars, reducing welding failures and ensuring high reliability and safety of the battery pack, while simplifying the tooling required for manufacturing.
Implementation Method 1
a first insulating member which is arranged between the lid and the positive electrode external terminal and includes a bus bar fixing section; and a second insulating member which is arranged between the lid and the negative electrode external terminal and includes a bus bar fixing section
Implementation Method 2
ensuring precise positioning and stable bonding through welding, thereby preventing welding failures
Data Source
AI summary
According to one embodiment, a battery includes a case, an electrode group, a lid, an external terminal and an insulating member. The external terminal includes a head section and an axial section extended from the head section. The axial section is caulked and fixed into a through hole in the lid. The insulating member is arranged between the lid and the external terminal. The insulating member includes a bus bar-fixing section.