Solid-State Battery Pack Assembly With Wedge Busbar Contacts
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Solution Overview
Problem
The existing battery pack assembly structures face challenges in maximizing the installation capacity of battery cells due to limited space and complexity in assembly processes, particularly in electric and hybrid vehicles, where high-voltage battery systems require efficient packing and electrical connection of multiple battery cells.
Innovation Solution
A battery pack configuration using a pack tray with a sensing circuit and sensing block, where battery cells are aligned and electrically connected via sensing busbars, allowing for a non-cooling, non-pressurizing, and non-welding structure that maximizes the volume ratio of battery cells, simplifies assembly, and reduces the number of components needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional battery module structures with cooling components and welding structures are used, then electrical connection and cooling functions are achieved, but the installation capacity and volume ratio of battery cells are reduced
Solution Approach 1:
The patent merges the sensing circuit with the pack tray by integrating sensing busbars directly onto the pack tray structure. This eliminates the need for separate sensing components and reduces the overall number of parts in the battery pack assembly, thereby increasing the volume available for battery cells while maintaining all necessary functions.
Solution Approach 2:
The pack tray is designed to serve multiple functions: it provides structural support, integrates sensing capabilities through built-in sensing busbars, and eliminates the need for separate cooling and welding structures. This multi-functional design reduces component count and maximizes battery cell installation capacity.
2Ease of operation
If multiple separate components are used for sensing, cooling, and welding, then specific functions are achieved, but the assembly process becomes complicated and time-consuming
Solution Approach 1:
By integrating the sensing circuit into the pack tray structure and using a non-welding connection method, the patent reduces the number of assembly steps. The sensing busbars are pre-integrated into the pack tray, eliminating the need for separate sensing component installation and complex welding operations, thereby simplifying the assembly process and reducing assembly time.
3Ease of repair
If a non-welding structure is used, then assembly is simplified and cell replacement is easier, but electrical connection reliability may be compromised
Solution Approach 1:
The sensing busbars serve as an intermediary component that provides both mechanical support and electrical connection. The busbars are designed with contact portions that reliably connect to the leads of battery cells through a simple insertion and pressing mechanism, ensuring both ease of replacement and reliable electrical connection without requiring welding.
4Quantity of substance
If cooling components and pressurizing structures are included, then battery cell control is improved, but the volume ratio of battery cells in the pack is reduced
Solution Approach 1:
The patent extracts and eliminates the separate cooling components and pressurizing structures from the battery pack design. By integrating necessary functions into the pack tray itself and using a non-welding, non-pressurizing structure, the design maximizes the volume available for battery cells while maintaining adequate control and monitoring capabilities through the integrated sensing circuit.
Data Source
AI summary
A battery pack may comprise a plurality of battery cells, each formed as a solid state secondary battery cell, aligned in a preset direction. The battery pack may comprise a pack tray, a sensing circuit unit coupled to the pack tray, a sensing block unit vertically coupled to the sensing circuit unit, and a tray cover coupled to an upper portion of the pack tray. The sensing circuit unit may comprise a plurality of sensing busbars that are electrically connected to leads in the plurality of battery cells. The sensing block unit may comprise a plurality of wedge members configured to tight-contact the leads and the plurality of sensing busbars.