Battery Pack Lead Connection via Mechanical Coupling

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Solution Overview

Problem

The existing welding process for connecting lead tabs and lead members in battery units generates heat, causing damage and has limited bonding strength and surface area, leading to inefficiencies in charging and discharging processes.

Innovation Solution

A battery pack design featuring a frame with perforated lead members and coupling members that mechanically and electrically connect lead tabs to the frame, enhancing surface contact area and reducing electrical resistance through a nut-and-bolt assembly and conductive plates, while using injection molding for structural integration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If welding process is used to connect lead tabs and lead members, then electrical connection is established, but heat is generated causing damage to nearby components and bonding strength is limited

Engineering Contradiction:

Improvebonding strengthVSAvoidheat damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the welding process (thermal/chemical connection method) with a mechanical coupling system using coupling members that physically connect lead tabs to lead members. This mechanical connection avoids heat generation while establishing reliable electrical contact through direct physical contact between conductive surfaces.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces coupling members as intermediary components between lead tabs and lead members. These coupling members serve as mediators that establish electrical connection without direct welding, thereby preventing heat damage to surrounding components while maintaining bonding strength through mechanical fastening.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If welding process is used to connect lead tabs and lead members, then connection is established, but surface area of contact is limited leading to increased electrical resistance

Engineering Contradiction:

Improveelectrical connection integrityVSAvoidelectrical resistance

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent transitions from point-contact welding to multi-point mechanical coupling using multiple coupling members distributed across the connection interface. This dimensional expansion from single-point to multi-point contact increases the effective surface area of electrical contact, thereby reducing electrical resistance while maintaining connection integrity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS8790823B2Battery unit and battery pack having less resistance and improved contacts

Publication Date: 2014.07.29 SAMSUNG SDI CO LTD

AI summary

A battery unit and a battery pack including the battery unit having reduced resistance along the leads. The battery unit includes a battery unit including an electrode assembly arranged within a pouch and lead tabs extending to an outside of the pouch and being electrically connected to the electrode assembly, a frame to support the battery unit, the frame including a first portion to accommodate the pouch of the battery unit and a second portion to accommodate the lead tabs, lead members arranged between the lead tabs and the second portion of the frame and a plurality of coupling members to mechanically couple together the lead tabs, the lead member and the second portion of the frame.