Battery Pack Side-Wall Sampling Structure for Higher Energy Density
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current battery packs face complexity and reduced space utilization due to the need for welding in connecting electrode terminals, which complicates operations and affects the pack's efficiency.
Innovation Solution
A battery pack design featuring a structural member that covers part of the side wall, with sampling assemblies connected through openings, utilizing side space to simplify sampling and improve space utilization and energy density, while also providing redundancy and stability to prevent sampling failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a sampling plate is used to connect electrode terminals, then the connection is achieved, but the welding process complicates the operation and reduces space utilization rate
Solution Approach 1:
The patent extracts the sampling function from the traditional welding-based connection system. By using a sampling plate with through-holes that allow direct access to electrode terminals without welding, the sampling operation is separated from the complex welding process, simplifying both manufacturing and operation while maintaining connection functionality
Solution Approach 2:
The sampling plate serves as an intermediary component between the electrode terminals and the sampling points. It provides a structured interface with through-holes that enable direct electrical contact without requiring welding operations, thus mediating between the need for connection and the desire for simplified operation
2Ease of manufacture
If a wire harness is used to connect electrode terminals, then the connection is achieved, but welding is needed which affects the space utilization rate
Solution Approach 1:
The patent removes the wire harness and welding components from the connection system. By using a sampling plate with through-holes that provide direct access to electrode terminals, the bulky wire harness and welding equipment are extracted from the battery pack design, improving space utilization while maintaining connection capability
Solution Approach 2:
The patent replaces the mechanical welding system with a direct contact system through the sampling plate. Instead of using welding (a thermal/mechanical process) to connect wire harnesses, the design uses through-holes in the sampling plate to establish direct electrical contact, eliminating the need for welding equipment and reducing space requirements
3Reliability
If the sampling assembly is placed inside the battery pack, then the sampling function is achieved, but the internal space is reduced
Solution Approach 1:
The patent moves the sampling function from the internal three-dimensional space to the external surface dimension. By placing the sampling plate on the battery shell surface with through-holes that access electrode terminals, the sampling assembly is relocated to another dimensional plane (the external surface), eliminating internal space occupation while maintaining sampling reliability
Solution Approach 2:
The sampling plate is designed to nest on the battery shell surface, utilizing the existing external space rather than consuming internal space. The through-holes in the sampling plate nest the sampling function within the battery shell structure, allowing the sampling assembly to be integrated into the external surface geometry without encroaching on internal volume
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A battery pack includes a battery, a first structural member, and a sampling assembly. The battery includes a battery shell and an electrode assembly arranged in the battery shell. The battery shell includes a bottom wall, a side wall and a top wall arranged in a first direction, and the side wall is connected to the bottom wall and the top wall. The first structural member covers at least part of the side wall. The first structural member has a first opening, and part of the surface of the side wall is exposed to the first opening. The sampling assembly includes a first sampling part, and the first sampling part is connected to a side wall through a first opening.