Battery Pack PTC Element Direct Welding Assembly
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Solution Overview
Problem
Existing battery pack assembly processes are complicated by the need for multiple connection and insulative members, leading to increased dead space, reduced capacity, and compromised structural stability against external forces.
Innovation Solution
A battery pack design featuring a PTC element with a non-bent connection plate directly welded to the battery case and an insulative mounting member with coupling protrusions and grooves for secure assembly, reducing the number of components and simplifying the assembly process while enhancing structural stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple connection members and insulative members are used to connect safety elements to the battery cell, then electrical connection and insulation are achieved, but the assembly process becomes complicated and dead space increases
Solution Approach 1:
The patent combines the connection member and insulative member into a single integrated component. The connection member includes both conductive portions for electrical connection and insulative portions for electrical insulation, eliminating the need for separate insulative members and simplifying the assembly process while maintaining reliable electrical connection and insulation.
Solution Approach 2:
The connection member is designed to perform multiple functions simultaneously: it provides electrical connection through its conductive portions, electrical insulation through its insulative portions, and mechanical support through its structural design. This multi-functional design reduces the total number of components needed in the battery pack.
2Reliability
If multiple insulative members are used to maintain electrical isolation, then electrical insulation is achieved, but the number of components increases and assembly becomes more complex
Solution Approach 1:
The insulative portions are integrated directly into the connection member structure, forming a unified component that provides both electrical connection and insulation functions. This eliminates the need for separate insulative members and reduces the total component count while ensuring reliable electrical insulation.
3Reliability
If adhesive is used to fix insulative members to the battery cell, then electrical insulation is maintained, but coupling strength is reduced and safety is compromised
Solution Approach 1:
The patent replaces the adhesive bonding mechanism with a mechanical engagement system. The connection member features engagement protrusions that fit into engagement grooves on the battery cell, providing strong mechanical coupling that is superior to adhesive bonding while maintaining electrical insulation through the insulative portions.
4Reliability
If nickel plates are fixed to aluminum battery case by welding, then electrical connection is achieved, but welding difficulty arises due to material incompatibility
Solution Approach 1:
The connection member is designed as a composite structure with conductive portions made of nickel or nickel alloy for electrical connection and insulative portions made of insulative material. This composite design allows the conductive portions to be directly welded to the aluminum battery case while the insulative portions provide electrical insulation, solving the material incompatibility issue.
5Reliability
If the connection plate is bent to connect PTC element to battery case, then electrical connection is achieved, but structural stability is reduced
Solution Approach 1:
Instead of bending the connection plate to achieve connection, the patent inverts the approach by providing engagement protrusions on the connection member that fit into engagement grooves on the battery case. This straight, unbent connection method maintains structural stability while achieving reliable electrical connection through the conductive portions.
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
This design simplifies the assembly process, minimizes dead space, maximizes battery capacity, and improves structural stability against external forces by reducing the number of components for electrical connection and insulation.
Implementation Method 1
the connection plate (a) being directly coupled to the top of the battery case by welding
Data Source
AI summary
Disclosed herein is a battery pack including a battery cell, an insulative mounting member coupled to the battery cell in a specific coupling structure, a positive temperature coefficient (PTC) element having a lower connection plate directly coupled to the battery cell while the lower connection plate is not bent, and an insulative cap, whereby the number of the members for electrical connection and electrical insulation is reduced, with the result that the assembly process of the battery pack is greatly simplified, the dead space is reduced, with the result that the capacity of the battery in the same-sized battery pack is maximized, and the structural stability of the battery pack against an external force is improved.