Battery Pack Holder Integrating Terminals and Components
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Solution Overview
Problem
The high manufacturing costs of battery packs, particularly due to complex terminal arrangements and component integration in lithium secondary batteries used for electric vehicles and hybrid electric vehicles.
Innovation Solution
A battery pack design featuring alternating positive and negative electrode terminals in stacked battery groups, with a holder accommodating electric components that connect to these terminals, allowing for simplified and cost-effective assembly by reducing the number of components and mounting man-hours.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex terminal arrangements and component integration are used in lithium secondary batteries, then electrical performance and reliability are improved, but manufacturing costs increase
Solution Approach 1:
The holder integrates multiple electric components (control circuit, protection circuit, connection terminals) into a single unified structure that accommodates them together. This merging reduces the number of separate components and mounting operations, thereby lowering manufacturing costs while maintaining reliable electrical connections for the battery pack
Solution Approach 2:
The holder serves multiple functions simultaneously: it provides structural support for battery cells, accommodates various electric components, establishes electrical connections between components and battery terminals, and provides mechanical mounting for the entire battery assembly. This multi-functionality reduces the need for separate dedicated structures for each function, reducing overall manufacturing cost
2Adaptability or versatility
If multiple electric components are integrated into the holder, then device functionality is improved, but assembly complexity increases
Solution Approach 1:
Multiple electric components are integrated into a single holder structure that provides unified mounting and electrical connection. This consolidation reduces assembly complexity by eliminating the need to separately mount and wire each component to the battery structure, while still providing the full range of required device functionalities
Solution Approach 2:
The holder acts as an intermediary structure that simplifies assembly by providing pre-configured mounting positions and electrical connection points for multiple components. Rather than directly assembling each component to the battery structure, the holder mediates the assembly process, reducing overall assembly complexity
3Loss of energy
If alternating positive and negative electrode terminals are arranged in stacked battery groups, then electrical resistance is minimized, but manufacturing precision requirements increase
Solution Approach 1:
The battery pack is divided into multiple stacked battery groups, with each group containing alternating positive and negative electrode terminals arranged in a systematic pattern. This segmentation into standardized groups makes it easier to achieve consistent terminal arrangement through modular assembly, reducing the overall manufacturing precision requirements while maintaining low electrical resistance through the alternating configuration
Data Source
AI summary
A battery pack includes battery groups, a holder, a positive electrode-connection bus bar, and a negative electrode-connection bus bar. The positive electrode-connection bus bar is connected to the positive electrode terminal having a highest potential in the first battery group and the second battery group which are electrically connected to each other in series. The negative electrode-connection bus bar is connected to the negative electrode terminal having a lowest potential in the first battery group and the second battery group which are electrically connected to each other in series. The positive electrode-connection bus bar and the negative electrode-connection bus bar are connected to the holder.