Battery Pack Interconnector Layout for Weld Access and Heat Venting
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Solution Overview
Problem
Battery packs face issues with heat generation, hot gas release, and weld failure due to short circuits, leading to reduced integrity and increased production and operational costs, especially in non-insulated cells with difficult welding and insulation gaps.
Innovation Solution
A battery pack design featuring top and bottom holders with interconnectors having connecting structures that allow easy access to positive terminals for welding, provide spaces for heat and gas dissipation, and ensure insulation, reducing the risk of short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to interconnect battery cells, then electrical conductivity is achieved, but weld failure risk increases and production cost increases
Solution Approach 1:
The patent introduces an interconnector as an intermediary component between battery cells. This interconnector features a connecting structure with a first member and second member that creates accessible welding surfaces. The interconnector mediates the electrical connection between cells while providing a standardized interface that simplifies the welding process and reduces variability in weld quality.
Solution Approach 2:
The patent modifies the physical parameters of the connection interface by designing the connecting structure with specific geometries (first member extending toward cell, second member extending parallel to longitudinal axis). This creates optimal welding surfaces with controlled distance and orientation, improving weld accessibility and consistency while reducing the complexity of welding operations.
2Reliability
If cell holders insulate negative terminals, then safety is improved, but welding accessibility to positive terminals deteriorates
Solution Approach 1:
The patent resolves the spatial conflict by extending the connecting structure in multiple dimensions. The first member extends toward the battery cell in one dimension, while the second member extends parallel to the longitudinal axis in another dimension. This multi-dimensional arrangement allows the welding surface to be positioned in a location that is both electrically isolated from negative terminals and accessible for welding operations on positive terminals.
3Power
If battery cells are arranged in series/parallel configurations, then desired voltage and capacity are achieved, but heat generation and short circuit risk increase
Solution Approach 1:
The patent segments the electrical connection function into distinct components: the interconnector separates the function of electrical connection from thermal management. By providing dedicated connecting structures for electrical conductivity and spaces for heat/gas dissipation, the system can achieve high power configurations while mitigating thermal risks through structural segmentation.
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
Enhances weld accessibility, improves connection reliability, and effectively dissipates heat and gases, thereby improving the battery pack's integrity and reducing production and operational costs.
Implementation Method 1
Each of the plurality of interconnectors comprises a hole and a connecting structure extending from the hole to enable contact with the positive terminal of the battery cell
Implementation Method 2
a space is provided between the second member of each of the plurality of interconnectors and each of the one or more top plates/bottom plates for expelling gases and dissipating heat from the battery pack
Implementation Method 3
The method further comprises the step of connecting the connecting structures of the plurality of interconnectors to the positive terminals of the plurality of battery cells. In one non-limiting example, the plurality of interconnectors are connected to the positive terminals of the plurality of battery cells by welding
Data Source
AI summary
A battery pack includes: a plurality of battery cells, each battery cell of the plurality of battery cells having a positive terminal and a negative terminal; one or more top holders and one or more bottom holders adapted to receive end portions of the plurality of battery cells; and one or more top plates arranged on the one or more top holders and one or more bottom plates arranged on the one or more bottom holders, each of the one or more top plates and the one or more bottom plates having a plurality of interconnectors and each of the plurality of interconnectors having a hole and a connecting structure extending from the hole to enable contact with the positive terminal of the battery cell.