Battery Pack Bus Bar Design for Reliable Electrical Connections
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Solution Overview
Problem
Existing battery pack structures that use a circuit board with through-holes are limited to coin-type batteries and require complex bending processes for metal connections, which can lead to stress and manufacturing complications, and often necessitate the use of insulating materials to prevent contact between components, increasing costs and complexity.
Innovation Solution
A battery pack design featuring a metal exterior case with a circuit board and bus bars that connect larger batteries without bending, using a quadrangular prism-shaped bus bars with integral flanges and side parts to provide structural support and prevent contact, eliminating the need for insulating materials and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a circuit board with through-holes is used to connect batteries, then coin-type batteries can be connected, but the mounting area is significantly reduced and larger batteries cannot be accommodated
Solution Approach 1:
The patent transitions from a planar connection method (through-holes in circuit board) to a three-dimensional connection structure (bus bar extending vertically from circuit board to battery). This dimensional change allows larger batteries to be connected without consuming additional circuit board area, as the connection extends in the Z-direction rather than requiring more board space.
Solution Approach 2:
The patent introduces a bus bar as an intermediary component between the circuit board and battery. This bus bar serves as a mediator that provides both electrical connection and mechanical support, enabling larger batteries to be connected without direct mounting on the circuit board, thus preserving board area while achieving adaptability.
2Reliability
If metal connections are bent to connect batteries, then electrical connection is achieved, but stress and manufacturing complications increase
Solution Approach 1:
The bus bar is pre-formed with the required three-dimensional shape (including vertical extensions and connection points) before assembly. This preliminary shaping eliminates the need for bending operations during assembly, reducing manufacturing complexity while maintaining reliable electrical connection. The connection geometry is prepared in advance rather than created through stress-inducing bending.
Solution Approach 2:
The patent replaces the mechanical bending process with a pre-formed structural solution. Instead of mechanically deforming metal connections during assembly, the bus bar is designed with its final three-dimensional configuration from the outset, substituting a complex mechanical forming operation with a simpler assembly process.
3Reliability
If insulating materials are used to prevent contact between components, then component contact is prevented, but cost and complexity increase
Solution Approach 1:
The bus bar's own three-dimensional structure serves the dual function of electrical connection and insulation. The vertical extensions and spatial configuration of the bus bar naturally prevent contact between components without requiring additional insulating materials. The structure insulates itself through its geometric design, eliminating the need for separate insulation components.
Solution Approach 2:
The bus bar is designed to perform multiple functions simultaneously: it provides electrical connection, mechanical support, and insulation. By integrating these functions into a single component, the patent eliminates the need for separate insulating materials, reducing both cost and device complexity while maintaining reliable contact prevention.
Data Source
AI summary
In a battery pack, a battery and a circuit board are appropriately connected. Provided is a battery pack including: an exterior case; a circuit board; a battery including a metal exterior can; and a metal member electrically connecting the battery and the circuit board, where an electrode part is provided on at least one end side of the battery, the circuit board and the electrode part are disposed to face each other, the metal member includes a board connection connected to the circuit board, an electrode connection connected to the electrode part, and a side part, the board connection is disposed to face the electrode connection with the side part interposed therebetween, and the board connection, the side part, and the electrode connection are integrally formed.