Battery Pack Pole Welding Layout to Protect Terminal Seals
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Solution Overview
Problem
The melting of plastic seals during welding of power battery pole terminals leads to sealing failure, compromising the integrity of power batteries in new energy vehicles.
Innovation Solution
A battery pack design with a top cover assembly that includes a pole with spaced end faces for welding, a bus-bar connection, and a sealing member, ensuring the welding position is away from the seal to prevent melting, and using an integrally injection-molded sealing member for enhanced sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pole terminal is connected to the external circuit structure by welding, then the electrical connection is achieved, but the plastic on the top cover is prone to melting due to high temperature, leading to sealing failure
Solution Approach 1:
The top cover assembly is divided into separate functional components: the top cover body, the pole terminal, and the sealing member. The sealing member is positioned to cover the connection between the pole terminal and top cover body, creating distinct zones for sealing and welding operations. This segmentation allows the welding process to occur on the pole terminal without directly affecting the plastic sealing portions.
Solution Approach 2:
The sealing member acts as an intermediary component between the pole terminal and the top cover body. It is specifically designed to cover and protect the connection interface during welding operations, absorbing or shielding against the thermal impact while maintaining the sealing function. The sealing member material is selected to resist the welding temperature or be positioned such that it protects the vulnerable plastic sealing areas.
2Strength
If the welding position is close to the seal, then the connection strength is improved, but the seal is prone to melting and sealing failure
Solution Approach 1:
Different regions of the top cover assembly are assigned different functional qualities: the pole terminal and connection areas are designed for strong electrical and mechanical connection, while the sealing areas are designed for thermal resistance and sealing performance. The sealing member is specifically positioned at the connection interface to provide localized protection against heat while maintaining sealing integrity.
Solution Approach 2:
The sealing member is pre-positioned to cover the connection interface between the pole terminal and top cover body before welding occurs. This beforehand protection creates a thermal buffer or shield that prevents the welding heat from directly affecting the plastic sealing portions, cushioning against the harmful thermal effects in advance of the welding process.
3Ease of manufacture
If a simple sealing structure is used, then the manufacturing cost is reduced, but the sealing performance under high temperature may be insufficient
Solution Approach 1:
The sealing member is designed to automatically perform its sealing function through its positioning and structural design. It is configured to cover the connection interface and adapt to the assembly geometry, providing self-aligning sealing without requiring complex adjustment mechanisms or additional sealing steps. The sealing structure serves itself by leveraging the assembly process to achieve proper positioning and sealing contact.
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
Reduces the risk of sealing failure by maintaining the integrity of the seal and ensuring sufficient heat dissipation, while maintaining strong connections and cost-effectiveness.
Implementation Method 1
a sealing member, which is arranged between the pole and the top cover member
Data Source
AI summary
The present application discloses a battery pack and an electric device. An end face of a pole of a single battery of the battery pack in a preset direction is connected to a bus-bar or a connector. In the present application, a position where the bus-bar or the connector is connected on the end face of the pole is spaced apart from an outer edge of the end face, that is, a welding position on the end face of the pole is spaced apart from the outer edge of the end face. In this way, the welding position on the end face of the pole can be kept as far away as possible from a sealing member, thereby reducing the risk of the melting of sealing member during welding and consequently reducing the risk of sealing failure of the sealing member.