Battery Pack Cell Connection Without Welding
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Solution Overview
Problem
Existing battery packs face challenges in efficient electrical connection and manufacturing processes, particularly in the can-type lithium secondary batteries, where welding and tubing processes can be complex and prone to errors, making them difficult to manufacture and replace individual cells within an assembled pack.
Innovation Solution
A battery pack design featuring a cylindrical case with a screw-shaped joining portion and a single-body integral structure combining the case and second connection member, which eliminates the need for welding by using a leaf spring connection member and a cap assembly with a positive polarity cap up and negative polarity case, ensuring secure electrical connections without additional welding or tubing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding and tubing processes are used to connect battery cells, then electrical connection reliability is improved, but manufacturing complexity and difficulty increase
Solution Approach 1:
The patent replaces the welding and tubing mechanical processes with a mechanical press-fit connection system. The connection member features a pressing portion that fits into a groove on the battery cell, creating a secure mechanical and electrical connection without requiring welding equipment or tubing operations. This substitution dramatically simplifies the manufacturing process while maintaining reliable electrical connectivity between cells.
2Reliability
If welding processes are used to connect battery cells, then electrical connectivity is ensured, but ease of manufacture and cell replacement deteriorate
Solution Approach 1:
The patent divides the connection system into separable components: a connection member with a pressing portion and a corresponding groove on the battery cell. This segmentation allows the connection to be made through simple insertion and pressing operations, enabling easy assembly and future disassembly for cell replacement, unlike permanent welding connections that require complex cutting and cleaning procedures.
Solution Approach 2:
The patent replaces the welding mechanical system with a simpler mechanical press-fit system. The connection member's pressing portion is designed to fit into the groove and be secured through pressing, creating a reliable electrical connection that can be easily manufactured and later disassembled for cell replacement without the need for welding equipment or complex procedures.
3Reliability
If additional welding and tubing components are added, then electrical connection stability is improved, but device complexity and manufacturing time increase
Solution Approach 1:
The patent merges the electrical connection function and the mechanical attachment function into a single integrated connection member. The connection member simultaneously provides electrical conductivity through its conductive material and mechanical attachment through its pressing portion that fits into the groove. This consolidation eliminates the need for separate welding and tubing operations, reducing manufacturing steps and time while ensuring stable electrical connection.
Data Source
AI summary
A battery pack includes a battery cell including an electrode assembly including a first electrode plate, a second electrode plate, and a separator that are wrapped, a case that receives the electrode assembly, a cap assembly including a cap up located on an upper part of the case and coupled to the case to be electrically connected to the electrode assembly, a first connection member electrically connected to the cap up of the battery cell, a joining portion on one area of an outer surface of the case, and a second connection member electrically connected to the joining portion at the one area of the outer surface of the case.