Battery Pack Output Welding Structure for Low-Resistance Connections
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Solution Overview
Problem
Current battery group output connection methods are complex, costly, and prone to unstable connections, leading to increased internal resistance and the risk of battery fires during vibration, with high assembly difficulties and space occupation.
Innovation Solution
An output structure for a battery group comprising an output terminal, a circuit board, a first terminal, and a conductive member, where the first terminal is electrically connected to the circuit board, and the conductive member is connected to the output terminal, providing a stable and low-cost connection that is resistant to loosening, using welding and conductive sheets for secure electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If locking screw connection method is used, then connection stability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent removes the locking screw from the connection system entirely, extracting the problematic mechanical fastening element that caused complexity and reliability issues. The connection is achieved through direct welding between the wire and conductive plate, eliminating the need for screws, holes, and associated assembly steps.
Solution Approach 2:
The patent replaces the mechanical screw-based connection system with a thermal welding process. Instead of using mechanical fastening elements (screws, holes, clamps), the invention uses heat and metallurgical bonding to create a permanent, reliable electrical and mechanical connection between components.
2Reliability
If locking screw connection method is used, then connection stability is improved, but manufacturing cost increases
Solution Approach 1:
The patent removes the locking screw and associated complex processing steps, dramatically simplifying the manufacturing process. The welding process requires fewer assembly steps, less specialized tooling, and reduced labor time compared to screw-based mechanical connections.
Solution Approach 2:
The patent replaces the mechanical screw connection system with a thermal welding process that is more cost-effective to manufacture. Welding eliminates the need for precision hole alignment, screw insertion, and torque control, resulting in lower manufacturing costs and higher production efficiency.
3Ease of manufacture
If wire and conductive plate are connected with locking screw, then connection is made, but connection stability deteriorates during vibration
Solution Approach 1:
The patent replaces the mechanical screw connection with a metallurgical weld joint that fuses the wire and conductive plate at the molecular level. This creates a permanent bond that is inherently resistant to vibration and mechanical stress, eliminating the loosening problem associated with threaded fasteners.
Solution Approach 2:
The welding process creates a composite joint structure where the wire and conductive plate materials are metallurgically bonded together, forming a unified connection that combines the properties of both materials while achieving superior mechanical and electrical performance under vibrational conditions.
4Ease of manufacture
If locking screw connection method is used, then connection is made, but internal resistance increases
Solution Approach 1:
The patent replaces the mechanical screw connection with a direct metallurgical weld that creates an intimate metal-to-metal contact between the wire and conductive plate. This eliminates the contact resistance inherent in mechanical connections, providing a low-resistance electrical path that reduces energy losses.
5Ease of manufacture
If conventional connection method is used, then connection is made, but space occupation increases
Solution Approach 1:
The patent removes the locking screw, washer, and associated mechanical fastening components, eliminating the extra space these elements occupy. The direct welding connection allows for more compact component layout and reduces the overall volume required for the battery group assembly.
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
The solution achieves a stable, low-cost, and secure connection that reduces the risk of battery fires by minimizing internal resistance and simplifying assembly, while also reducing production costs and space requirements.
Implementation Method 1
the conductive member is electrically connected to the circuit board; the first terminal is welded to the conductive member; and the output terminal is welded to the conductive member or the first terminal
Implementation Method 2
the first terminal is welded to the conductive member; and the output terminal is welded to the conductive member or the first terminal
Data Source
AI summary
An output structure of a battery group, including an output terminal, a circuit board, a first terminal, and a conductive member. The first terminal is electrically connected to the circuit board; the conductive member is electrically connected to the circuit board; the first terminal is welded to the conductive member; and the output terminal is welded to the conductive member or the first terminal. In the output structure provided by this application, the output terminal, the first terminal, and the conductive member are fixedly connected by welding. The output structure has advantages such as stable connection, stable welding quality, easy control, and being not easy to loosen, and can effectively avoid the serious heating caused by the increase of internal resistance at the joint, and thus can avoid the risk of a battery fire caused by the heating.