Battery Module Press-Fit Terminal Connection Design
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Solution Overview
Problem
Conventional battery modules face instability in electrical connections between electrode leads and sensing terminals, prone to disconnection due to external pressure and vibration, and errors in voltage detection occur during the soldering process, reducing energy density and increasing manufacturing complexity.
Innovation Solution
A battery module design featuring electrode leads with protruding parts that are press-fit into sensing terminals, eliminating the need for welding or soldering, and using adhesive members and a sensing cover to secure the connections, ensuring stable electrical contact and simplified manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding or soldering is used to connect electrode leads and sensing terminals, then electrical connection stability is improved, but manufacturing complexity and error risk increase
Solution Approach 1:
The patent replaces welding/soldering (thermal-chemical joining) with a mechanical press-fit connection system. The sensing terminal includes a pressing portion that mechanically engages with the electrode lead through direct pressure application, eliminating the need for complex thermal processing while maintaining stable electrical connection.
Solution Approach 2:
The patent introduces a pressing portion as an intermediary mechanical element between the sensing terminal and electrode lead. This pressing portion acts as a mediator that transfers and distributes mechanical pressure to create a stable contact interface, replacing the direct thermal-chemical bonding process with a controlled mechanical interaction.
2Reliability
If welding or soldering processes are used, then electrical connection is achieved, but manufacturing time and energy consumption increase
Solution Approach 1:
The patent replaces time-consuming welding/soldering processes with a rapid mechanical press-fit operation. The pressing portion applies direct mechanical pressure to establish electrical connection instantly, eliminating the heating, melting, and cooling cycles inherent in thermal joining methods.
Solution Approach 2:
The patent skips the intermediate heating and cooling phases of welding/soldering by using direct mechanical pressing. The connection is established in a single rapid action without undergoing the time-consuming thermal transformation cycles, thus accelerating the manufacturing process.
3Ease of manufacture
If mechanical pressing is used to connect electrode leads and sensing terminals, then manufacturing simplicity is improved, but connection stability under external pressure and vibration deteriorates
Solution Approach 1:
The patent applies local quality by designing the sensing terminal with a specifically shaped pressing portion that concentrates mechanical pressure at the precise contact point with the electrode lead. This localized pressure distribution creates a mechanically robust connection that resists external forces while maintaining manufacturing simplicity.
Solution Approach 2:
The pressing portion is designed with a curved or rounded contact surface that better matches the geometry of the electrode lead. This curved interface distributes pressure more effectively and creates a mechanically interlocking connection that maintains stability under vibration and external pressure while keeping the manufacturing process simple.
4Reliability
If welding or soldering is used, then electrical connection is achieved, but energy density of the battery module decreases due to additional processes
Solution Approach 1:
The patent replaces energy-intensive welding/soldering processes with a low-energy mechanical press-fit operation. The pressing portion establishes electrical connection through direct mechanical pressure without requiring external heat sources, power consumption for melting materials, or associated thermal management systems, thus preserving battery module energy density.
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 enhances the stability of electrical connections between electrode leads and sensing terminals, reduces manufacturing errors, and maintains energy density by eliminating unnecessary processes, resulting in a more reliable and efficient battery module.
Implementation Method 1
the protruding part of each electrode lead being press-fit into a corresponding one of the sensing terminals which compress around the protruding part
Data Source
AI summary
A battery module according to the present disclosure includes a cell assembly including a plurality of battery cells stacked in a vertical direction, each battery cell having an electrode lead in a shape of a plate that protrudes forward in a depth direction perpendicular to the vertical direction, the electrode lead being bent for surface contact in the vertical direction with an adjacent electrode lead, the electrode lead having a protruding part that protrudes forward in the depth direction from a front side end thereof, and a sensing terminal module having a plurality of sensing terminals made of an electrically conductive material and a plurality terminal seating holes in which corresponding ones of the sensing terminals are seated and supported, the protruding part of each electrode lead being press-fit into a corresponding one of the sensing terminals which compresses around the protruding part.