Battery Pack Integrated Fastening and Electrical Coupling
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Solution Overview
Problem
Existing battery packs require complex manufacturing processes and structures to fix the cell holder and establish electrical connections, increasing the number of assembly steps and potential for structural complications.
Innovation Solution
A battery pack design featuring a holder unit with a cell holder, flange, lead member, and bus bar that simplifies the assembly by using a fastening member to couple the lead tab, bus bar, and flange to the pack case, reducing the number of assembly processes and enhancing structural simplicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate fastening members and coupling structures are used to fix the cell holder and establish electrical connections, then reliable mechanical fixation and electrical connection are achieved, but the number of assembly steps and structural complexity increase
Solution Approach 1:
The patent combines the mechanical fastening function and electrical connection function into a single integrated coupling structure. The coupling structure includes a coupling body that simultaneously engages with the cell holder for mechanical fixation and establishes electrical contact through integrated contact elements, eliminating the need for separate fastening members and reducing assembly complexity
Solution Approach 2:
The coupling structure is designed to perform multiple functions simultaneously: it provides mechanical support and fixation for the cell holder, establishes electrical connections between cells, and enables modular assembly. This multi-functional design reduces the total number of components needed in the battery pack
2Reliability
If multiple separate components are used for fixing and electrical connection, then functional reliability is improved, but the number of manufacturing processes increases
Solution Approach 1:
The coupling structure integrates multiple functions into a single manufacturable component. The coupling body is designed to be produced as one piece or pre-assembled unit that combines fastening elements and electrical contact elements, reducing the number of manufacturing steps from multiple separate component productions to a more streamlined process
3Device complexity
If a simplified coupling structure is used, then assembly complexity is reduced, but structural integrity may be compromised
Solution Approach 1:
The integrated coupling structure maintains structural integrity by combining reinforcement features directly into the coupling body design. The coupling body includes strengthened engagement surfaces and integrated support elements that provide the necessary mechanical strength while keeping the overall structure simple and reducing the number of separate components
Data Source
AI summary
A battery pack is disclosed. The battery pack includes a battery holder, a lead terminal, a bus bar, and a pack case. The battery holder includes a cell holder accommodating a plurality of battery cells and a flange extending outwardly from the cell holder. The lead terminal includes a lead plate and a lead tab, the lead plate covering electrodes of the battery cells, and the lead tab extending from the lead plate toward the flange. The bus bar is configured to form an electrical path between the lead tab and an external terminal. The pack case includes a coupler, and the external terminal is formed on the pack case. A fastener is inserted into the bus bar, the lead tab, and the flange, and the fastener is engages with the coupler.