Battery Lid Busbar Layout for Simpler Cell Pack Connections
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Solution Overview
Problem
Existing battery designs face challenges in efficiently connecting a cell pack to terminals, requiring cumbersome and complex cable configurations and assembly processes, especially when terminals are supported by the lid, necessitating thick cables that must be folded or coiled under the lid.
Innovation Solution
The implementation of a battery comprising a housing, a cell pack supported within the housing, and a lid configured to close an open end of the housing, where busbars electrically couple the cell pack to terminals, with components like battery protection switches and fuses supported by the lid, allowing high-voltage connections post-lid assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thick cables are used to connect cell pack to terminals supported by lid, then electrical connection is achieved, but assembly complexity and cable management difficulty increase
Solution Approach 1:
The patent extracts the electrical connection function from traditional cable-based systems and relocates it to the lid structure itself. Conductive elements are integrated directly into the lid, eliminating the need for separate thick cables to bridge the cell pack and terminals. This extraction principle resolves the contradiction by removing the cumbersome cable management requirement while maintaining reliable electrical connection through the lid's inherent conductive pathways.
Solution Approach 2:
The patent merges the functions of the lid (structural closure) and the electrical connection system into a single integrated component. The lid simultaneously serves as both the protective cover and the conductive pathway for electrical current. This merging eliminates the need for separate cable assemblies, reducing device complexity while ensuring reliable electrical connection between the cell pack and terminals through the unified lid structure.
2Reliability
If traditional cable connections are used between cell pack and terminals, then electrical coupling is achieved, but assembly process becomes cumbersome
Solution Approach 1:
The patent implements preliminary action by pre-integrating conductive elements into the lid structure during lid manufacturing, before final battery assembly. The electrical connection pathways are established in advance within the lid, so that during battery assembly, workers simply need to position the lid and secure it to the housing. This eliminates the need for complex on-site cable routing and connection procedures, dramatically simplifying the assembly process while ensuring reliable electrical coupling from the moment the lid is installed.
Solution Approach 2:
The lid serves as an intermediary structure that facilitates electrical coupling between the cell pack and terminals without requiring direct cable connections. The conductive elements in the lid act as a mediator, providing a built-in electrical pathway that simplifies the connection process. This intermediary approach eliminates the need for manual cable installation and routing, making the assembly process more straightforward while maintaining reliable electrical coupling.
3Adaptability or versatility
If cables are folded or coiled under the lid, then connection flexibility is achieved, but space utilization and assembly efficiency decrease
Solution Approach 1:
The patent extracts the electrical connection function from external cables and relocates it to the lid structure. By removing the need for separate cables that would require folding or coiling, the design eliminates the space-consuming cable management requirements. The conductive elements are built into the lid, providing connection flexibility through the lid's own structure without requiring additional space for cable routing, folding, or coiling operations.
Solution Approach 2:
The patent transitions from a three-dimensional cable routing problem to a two-dimensional planar solution by integrating conductive elements directly into the lid surface. Instead of cables extending in multiple directions and requiring volumetric space for folding and coiling, the electrical connection is achieved through planar conductive pathways on the lid. This dimensional change eliminates the need for space-consuming cable management while maintaining connection flexibility through the lid's integrated design.
Data Source
AI summary
A battery has a housing, a cell pack supported within the housing, and a lid configured to close an open end of the housing. A first terminal is supported by the lid. A first busbar is configured to electrically couple the cell pack to the first terminal. A first electrical component is supported by the lid and electrically coupled between the first busbar and the first terminal.