Battery Pack Bus Bar Pressing for Terminal Height Variation
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Solution Overview
Problem
Conventional battery pack manufacturing methods result in varying terminal heights, leading to large gaps between bus bars and terminals, which can cause bonding failures during welding, affecting production efficiency.
Innovation Solution
The method involves compressing battery cells from both sides, inserting them into a case with terminals facing upwards, positioning bus bars to overlap the terminals, and using a pressurizing jig to press the bus bars towards the case bottom from a start position corresponding to the farthest terminal's height, ensuring consistent bonding despite height variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the stacked body is pressed from above by a pressurizing jig to be press-fitted into the cover case, then the battery cells are secured in the case, but heights of the terminals vary among the battery cells causing large gaps between terminals and bus bars
Solution Approach 1:
The bus bars are positioned on the stacked battery cells before the press-fitting operation. This preliminary positioning ensures that when the pressurizing jig applies pressure from above, the bus bars are already in place to receive the terminals, allowing the pressing force to simultaneously secure the battery cells and establish proper contact between terminals and bus bars, eliminating the height variation problem
Solution Approach 2:
Instead of pressing the battery cells from below or the sides, the patent applies pressure from above using the pressurizing jig. This inverted pressing direction allows the bus bars positioned on top to be compressed together with the terminals, ensuring uniform contact and eliminating gaps that would occur with traditional pressing methods
2Stability of the object's composition
If binding jigs are used to hold the stacked body from both sides, then the battery cells are securely stacked, but the apparatus becomes larger and heavier
Solution Approach 1:
The patent removes the binding jigs from the manufacturing process entirely. Instead of using external binding fixtures to hold the stacked battery cells, the design relies on the case structure and the press-fitting operation to secure the cells. This extraction of unnecessary components simplifies the apparatus, reducing its size and weight while maintaining stacked body stability
Solution Approach 2:
The battery cell stack is designed to be self-sufficient during the stacking process. The cells are stacked and then directly press-fitted into the case without requiring external binding jigs for support. The case itself provides the necessary containment and structural support, eliminating the need for additional binding apparatus
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 small gaps between bus bars and terminals, preventing bonding failures and improving production efficiency by ensuring reliable connections during the manufacturing of battery packs.
Implementation Method 1
moving a pressurizing jig so as to press the plurality of bus bars toward a bottom surface of the case from a pressurization start position corresponding to a height position of the terminal of the battery cell farthest from the bottom surface
Data Source
AI summary
A method of manufacturing a battery pack of the present disclosure stacks a plurality of battery cells such that one surfaces face the same direction and compresses the battery cells from both sides, inserts the compressed battery cells into the case such that the one surfaces are positioned on an open end side of the case, disposes a plurality of bus bars on the one surfaces of the battery cells so as to overlap the corresponding terminal, moves a pressurizing jig so as to press the bus bars toward a bottom surface of the case from a pressurization start position corresponding to a height position of the terminal of the battery cell farthest from the bottom surface, and bonds each of the plurality of bus bars to the corresponding terminal.