Battery Pack Connection Tab With Coupling Member For Automated Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for manufacturing battery packs are inefficient due to difficulties in resistance welding, leading to high failure rates and production costs, particularly in connecting electrode tabs to protection circuit modules.
Innovation Solution
A battery pack design featuring a connection tab with a coupling member and a concave portion, integrated with a protection circuit module, where a heating member is used to apply heat for electrical connection, allowing for an automated and improved welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resistance welding using welding rods is used to connect electrode tabs to protection circuit modules, then electrical connection is achieved, but the manufacturing process becomes complex and difficult to automate
Solution Approach 1:
The invention extracts the welding rods from the final connection structure, using them only as temporary tools during assembly. The coupling members remain on the connection tabs after the welding rods are removed, providing a simplified automated connection method without requiring permanent welding rod presence in the battery pack structure.
Solution Approach 2:
The invention introduces coupling members as intermediary elements that facilitate the connection between connection tabs and protection circuit modules. These coupling members enable automated welding processes by providing standardized connection interfaces, while the welding rods serve as temporary mediators during the assembly process before being removed.
2Reliability
If conventional resistance welding with welding rods is used, then electrical connection is established, but the manufacturing efficiency decreases and failure rate increases
Solution Approach 1:
The invention applies preliminary action by pre-installing coupling members on the connection tabs before the welding process. This preparation enables automated welding systems to efficiently connect the protection circuit modules without manual intervention, thereby increasing manufacturing efficiency while maintaining connection reliability through the standardized coupling interface.
Solution Approach 2:
The coupling members are designed to enable self-aligning and self-securing during the automated welding process. The connection tabs with pre-installed coupling members automatically position themselves relative to the protection circuit modules, allowing the welding process to proceed without complex positioning mechanisms and improving overall manufacturing efficiency.
3Reliability
If welding rods are used for resistance welding, then connection is achieved, but production cost increases
Solution Approach 1:
The invention applies the principle of disposable objects by using welding rods only as temporary consumable tools during the assembly process. The rods are removed after welding, leaving only the permanent coupling members that provide lasting electrical connections. This approach reduces production costs by eliminating the need for expensive permanent welding rod installations while maintaining reliable electrical connections.
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 simplifies the manufacturing process, reduces failure rates, and lowers production costs by enabling an automated welding process that enhances productivity.
Implementation Method 1
applying heat to the heating member so that the protection circuit module is electrically connected to the bare cells
Implementation Method 2
an electrode tab connected to a bare cell was coupled to a circuit board of a PCM through resistance welding using a welding rod
Data Source
AI summary
A battery pack and a manufacturing method thereof are provided. A battery pack includes one or more bare cells. A protection circuit module is provided with a circuit portion and disposed parallel to a length direction of at least one of the bare cells. A connection tab is provided with at least one coupling member so as to electrically connect the protection circuit module to the bare cells. The connection tab is integrally formed with a connection end portion connected to the protection circuit module. Accordingly, a certain amount of coupling member is previously coupled to the connection tab, so that it is possible to improve the problem in a welding process and to implement an automated welding process.