Battery Pack Connection Tab Fastening Mechanism
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Solution Overview
Problem
The existing battery pack manufacturing process faces challenges in efficiently connecting connection tabs to electrical conductors like coverlays, particularly due to difficulties in soldering, which complicates the manufacturing process and affects the quality of the battery pack.
Innovation Solution
The connection tab and spacer are physically fastened to each other, allowing for improved fixing and omitting the need for soldering, using a fastening member to connect the tab and conductor, thereby simplifying the manufacturing process and ensuring consistent quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to connect the connection tab and the coverlay, then electrical connection is achieved, but the manufacturing process becomes complicated and quality consistency is affected
Solution Approach 1:
The patent replaces the soldering process (thermal/chemical connection method) with a mechanical fastening system consisting of a fastening member that physically secures the connection tab to the coverlay. This substitution eliminates the complexity and quality variability associated with soldering while maintaining reliable electrical connection.
Solution Approach 2:
The patent introduces a fastening member as an intermediary component between the connection tab and the coverlay. This fastening member serves as a mediator that provides a simple, reliable mechanical connection, replacing the direct soldering process and enabling consistent assembly without thermal or chemical processes.
2Productivity
If soldering operation is performed to join connection tab and conductor, then electrical connection is established, but manufacturing time and process steps increase
Solution Approach 1:
The patent replaces the time-consuming soldering operation with a rapid mechanical fastening process. The fastening member can be installed quickly through simple insertion or clipping actions, eliminating the heating, cooling, and inspection cycles required for soldering, thereby significantly improving manufacturing efficiency.
Solution Approach 2:
The patent separates the connection tab and conductor assembly into distinct components that can be independently prepared and then quickly assembled using the fastening member. This segmentation allows for parallel manufacturing of components and simplifies the final assembly step, reducing overall manufacturing time compared to the integrated soldering process.
Data Source
Figure 1
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AI summary
A battery pack comprising a battery cell, a connection tab connected to the said battery cell, a protective circuit module, a conductor that electrically connects the connection tab with the protective circuit module and a spacer that is situated between the conductor and the battery cell. At least one of the spacer and the connection tab comprises a fastening formation that secures the location of the spacer and the connection tab relative to each other.