Battery Pack Assembly with Pre-Formed Electrode Tabs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery pack manufacturing processes face challenges in handling and mass production due to the need for precise alignment of power collection tabs with fixing tool holes, which is cumbersome and not suitable for large-scale production.
Innovation Solution
A battery pack design featuring cells with protruding electrode tabs connected by conductive members and bus bars, allowing for easier assembly and electrical connection between cells, with bus bars connecting adjacent frame members to simplify the stacking and connection process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If power collection tabs are bent to align holes with fixing tools, then electrical connection is achieved, but handling difficulty increases and mass production becomes cumbersome
Solution Approach 1:
The power collection tabs are pre-formed with holes positioned at locations that will naturally align with the fixing tools during assembly, eliminating the need for bending operations. This preliminary preparation of the tabs allows for straightforward insertion and fixation without requiring troublesome handling or precise alignment maneuvers during the assembly process.
2Reliability
If precise alignment of power collection tabs with fixing tool holes is required, then electrical connection reliability improves, but manufacturing complexity increases
Solution Approach 1:
The tabs are pre-formed during the battery cell manufacturing process with holes positioned at predetermined locations that correspond to the fixing tool hole positions. This preliminary positioning eliminates the need for complex alignment procedures during assembly, reducing manufacturing complexity while maintaining electrical connection reliability.
Solution Approach 2:
The fixing tools serve as intermediaries that simplify the connection process. The tools are designed with features that guide and position the pre-formed tabs, making the alignment process straightforward rather than requiring precise manual positioning or complex alignment mechanisms.
3Manufacturing precision
If bending of power collection tabs is performed for alignment, then hole positioning is achieved, but manufacturing time increases
Solution Approach 1:
The holes in the power collection tabs are formed at predetermined positions during the battery cell manufacturing process, before assembly. This preliminary formation of properly positioned holes eliminates the need for time-consuming bending operations during mass production, thereby improving productivity while maintaining the required manufacturing precision for hole positioning.
Data Source
AI summary
A battery pack includes: cells, and electrode tabs including a positive electrode tab and a negative electrode tab which are connected with the power generation element, and which are provided to protrude from end portions of the outer member; frame members each including a front surface and a back surface on which the pair of the cells are mounted; conductive members each of which is disposed on the frame member, and each of which electrically connects the electrode tabs of the pair of the cells; and bus bars each of which electrically connects the conductive members disposed on the frame members of the plurality of the stacked frame members, and which are adjacent in a stacking direction.