Battery Pack Connection Circuit Part Stacked Layer Design
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Solution Overview
Problem
Existing battery packs face challenges in achieving a balance between weight, volume, and output capacity, with conventional designs often resulting in bulky and heavy configurations that complicate manufacturing and reduce convenience.
Innovation Solution
A battery pack design featuring a modularized connection circuit part with a heat-blocking layer, busbar, and thermal fusion layers, which forms a compact and lightweight structure by electrically connecting battery cells in parallel and series configurations, while also providing a charge/discharge path and status information acquisition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional battery pack designs are used, then output capacity can be achieved, but weight and volume increase resulting in bulky configurations
Solution Approach 1:
The connection circuit part is divided into multiple functional layers including a first connection wiring layer, a second connection wiring layer, a busbar layer, and a circuit board layer. This segmentation allows each layer to perform specific functions efficiently, reducing overall material usage and weight while maintaining required output capacity through optimized electrical connections.
Solution Approach 2:
The patent transitions from conventional planar connection layouts to a three-dimensional stacked configuration where connection wirings and busbars are arranged in multiple vertical layers. This dimensional change enables more compact space utilization, reducing the horizontal footprint and allowing for lighter overall packaging while achieving the same electrical connectivity and capacity.
2Quantity of substance
If conventional battery pack designs are used, then output capacity can be achieved, but volume increases resulting in bulky configurations
Solution Approach 1:
The connection circuit components are nested within each other in a compact stacked arrangement where the first connection wiring is positioned between the battery cell and the second connection wiring, with the busbar and circuit board layers integrated above. This nesting minimizes the overall volume by eliminating empty spaces and achieving dense packing of all connection elements.
Solution Approach 2:
By arranging connection elements in multiple vertical layers rather than spreading them out horizontally, the patent reduces the battery pack's horizontal volume while maintaining all necessary electrical connections for the required output capacity.
3Reliability
If conventional connection circuit designs are used, then electrical connections can be established, but manufacturing complexity increases
Solution Approach 1:
Multiple connection functions are merged into an integrated connection circuit part where the first connection wiring, second connection wiring, busbar, and circuit board are combined in a single stacked structure. This merging reduces the number of separate manufacturing steps and assembly operations required, simplifying the manufacturing process while ensuring reliable electrical connections through the integrated design.
4Weight of stationary object
If compact connection circuit design is implemented, then weight and volume are reduced, but manufacturing precision requirements increase
Solution Approach 1:
The connection wirings, busbar, and circuit board are pre-assembled and pre-positioned in their final stacked configuration before being integrated with the battery cell. This preliminary action ensures precise alignment and positioning is achieved during the initial assembly stage, reducing the need for complex adjustments later and maintaining manufacturing feasibility despite the compact design.
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 design enhances manufacturing convenience, achieves a lightweight and compact battery pack with reduced volume and weight compared to packs with similar output and capacity, while ensuring efficient charge/discharge operations and status monitoring.
Implementation Method 1
thermal fusion layers pressed to face each other with the connection wiring, the heat-blocking layer, and the busbar together therebetween
Data Source
AI summary
A battery pack includes at least one battery cell and a connection circuit part electrically connected to the at least one battery cell, and the connection circuit part includes a connection wiring arranged on the at least one battery cell and electrically connected to the at least one battery cell, a heat-blocking layer between the at least one battery cell and the connection wiring, a busbar arranged at at least any of a position above or below the heat-blocking layer and connected to the at least one battery cell, and thermal fusion layers pressed to face each other with the connection wiring, the heat-blocking layer, and the busbar together therebetween.