Battery Pack Bonding Part Holes for Welding Alignment
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Solution Overview
Problem
Existing battery pack manufacturing methods face challenges in accurately welding electrode tabs to connection tabs, leading to potential welding failures and inefficiencies in the assembly process.
Innovation Solution
The battery pack design incorporates bonding part holes in the lower case for precise welding of electrode tabs to connection tabs, using nickel or nickel alloy bonding parts with insulating layers, and a rib for accurate positioning, simplifying the manufacturing process and preventing welding failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional welding methods are used to join electrode tabs to connection tabs, then welding can be performed, but welding failures occur due to inaccurate positioning
Solution Approach 1:
The lower case is pre-formed with bonding part holes at precise locations before assembly. These holes serve as predetermined positioning features that guide the bonding parts to exact locations, ensuring accurate alignment between connection tabs and electrode tabs during welding operations.
Solution Approach 2:
Bonding part holes act as intermediary structures that mediate between the lower case and the bonding parts. These holes provide both positioning and support functions, ensuring that bonding parts are accurately located and securely held during the welding process, thereby preventing welding failures.
2Manufacturing precision
If multiple separate steps are used for assembling connection tabs and welding electrode tabs, then positioning can be controlled, but manufacturing complexity increases
Solution Approach 1:
The bonding part holes integrate multiple functions into a single structural feature: positioning, support, and alignment. By combining these functions into one element, the design eliminates the need for separate positioning fixtures and support structures, thereby simplifying the overall assembly process while maintaining precise positioning control.
Solution Approach 2:
The bonding part holes serve multiple purposes simultaneously: they position the bonding parts, support the connection tabs during welding, and ensure accurate alignment. This multi-functionality reduces the number of separate components and steps required, simplifying the manufacturing process while maintaining precision.
3Ease of manufacture
If connection tabs are not firmly positioned, then assembly is easier, but welding failures occur
Solution Approach 1:
The bonding part holes automatically position and secure the bonding parts through their structural design. As bonding parts are inserted into the holes, they are self-aligned and self-secured without requiring additional positioning operations or external fixtures, ensuring firm positioning while maintaining ease of assembly.
4Device complexity
If bonding part holes are not used, then manufacturing process is simpler, but welding accuracy decreases
Solution Approach 1:
The lower case is segmented with discrete bonding part holes at specific locations rather than using a continuous or complex positioning structure. This segmentation approach provides precise localization for each welding point while keeping the overall structure simple and easy to manufacture.
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 ensures accurate and reliable welding of electrode tabs to connection tabs, enhancing the manufacturing efficiency and preventing welding failures by fixing the connection tabs at precise positions, thereby improving the overall assembly process of the battery pack.
Implementation Method 1
welding the first electrode tabs and the second electrode tabs to corresponding ones of the bonding parts
Data Source
AI summary
A battery pack having a case where connection tabs can be accurately positioned within the case and where welding holes in the case are formed to provide access to a welding rod and to allow heat to escape. Connection tabs are fixed into a lower case, batteries are arranged in the case, and then a welding process is performed to attach electrode tabs of the battery to the connection tabs so that the batteries can be connected together, to an external terminal and to a protection circuit module.