Battery Pack Flat Conductor Element Automated Assembly
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Solution Overview
Problem
Battery packs are predominantly manufactured by hand due to the complexity of assembly, leading to high production costs and quality control challenges, which are difficult to maintain consistently.
Innovation Solution
A battery pack design where the battery cell is positioned on a flat conductor element and electrically connected using a separating or forming process between connecting elements and the conductor element, allowing for mechanical attachment and electrical contact without soldering, facilitating automated production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual assembly is used for battery pack manufacturing, then assembly flexibility is maintained, but production costs increase and quality consistency deteriorates
Solution Approach 1:
The battery pack is divided into modular components: battery cells with connecting elements, flat conductor elements, and housing sections. This segmentation allows each module to be manufactured separately using automated processes, then assembled systematically, reducing overall manufacturing complexity and cost while maintaining flexibility.
Solution Approach 2:
The connecting elements serve multiple functions simultaneously: they provide electrical connection between battery cells, mechanical attachment to the conductor element, and structural support. This multi-functionality reduces the number of separate components needed, simplifying assembly and enabling automated manufacturing while controlling costs.
2Device complexity
If manual assembly is used for battery pack manufacturing, then complex assembly steps can be handled, but quality control consistency deteriorates
Solution Approach 1:
Connecting elements are pre-attached to battery cells during cell manufacturing, and conductor elements are pre-prepared with contact surfaces. This preliminary preparation ensures that when assembly occurs, the components are ready for consistent automated joining, improving quality control while managing assembly complexity.
Solution Approach 2:
Traditional manual soldering and mechanical fastening operations are replaced with automated forming processes and press-fit mechanisms. The connecting elements are mechanically formed into the conductor element through controlled deformation, providing consistent electrical and mechanical connections without manual intervention, thus improving quality consistency.
3Reliability
If traditional connecting methods are used, then reliable electrical connection is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The electrical connection function and mechanical attachment function are merged into a single integrated connecting element. This element simultaneously provides electrical conductivity and structural bonding between battery cells and the conductor element, eliminating the need for separate electrical connectors and mechanical fasteners, thus reducing manufacturing complexity while maintaining reliable electrical connection.
Solution Approach 2:
The connecting elements undergo controlled plastic deformation during the forming process, changing their physical parameters (shape, rigidity) to create a permanent mechanical and electrical connection. This parameter change transforms the connecting element from a flexible conductor into a rigid, bonded joint, ensuring reliable electrical connection through a simplified single-step process.
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 and stabilizes the connection between battery cells and conductor elements, reducing assembly steps and costs while enabling consistent quality and efficient automated manufacturing.
Implementation Method 1
A separating process and/or a forming process takes place between the connecting element and the conductor element. As a result, the connecting element is mechanically connected to the conductor element.
Implementation Method 2
The connecting element is positioned or placed on the ladder element and pressed against the ladder element.
Data Source
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AI summary
A battery pack (10) having at least one battery cell (12), wherein the battery cell (12) is coupled and electrically conductively connected to connecting elements (18) at its battery poles (14, 16), is configured and developed in respect of simplified production with simple structural means in such a way that the battery cell (12) is positioned on a flat conductor element (20) and that the battery cell (12) is electrically conductively connected to the conductor element (20) by a separating process and/or a shaping process between connecting elements (18) and conductor element (20) and is fixed to or on the conductor element (20). A method for producing a battery pack (10) is specified.