Battery Pack Ring Terminal Assembly for Orientation-Free Coupling
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Solution Overview
Problem
Existing battery packs face challenges in efficiently coupling ring terminals to busbar plates due to orientation-dependent coupling processes, leading to deformation of the busbar plate ends, increased pack size, and reduced energy density.
Innovation Solution
A battery pack design where the busbar plate's external coupling portion is configured to be short and flat, allowing the ring terminal to be coupled irrespective of orientation, with a pressing portion inserted into a punched portion of the battery pack case, and using a rivet for secure fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pressing portion protrudes from the ring terminal to press the wire, then the wire coupling is secured, but the ring terminal must be installed in a specific orientation causing manufacturing delays
Solution Approach 1:
The ring terminal employs asymmetric design elements (pressing portion and connection portion) that are positioned to work effectively regardless of the terminal's rotational orientation, allowing the asymmetric features to function in multiple orientations rather than requiring a specific installation angle
Solution Approach 2:
The ring terminal is designed with universal coupling capability where the pressing portion and connection portion can perform their functions effectively in any rotational orientation, making the component multi-orientational and eliminating the need for precise alignment during assembly
2Manufacturing precision
If the ring terminal is oriented with the pressing portion protruding upwards to prevent busbar plate deformation, then the busbar plate end is not bent, but the coupling process becomes orientation-dependent and time-consuming
Solution Approach 1:
The ring terminal uses asymmetric positioning of the pressing portion and connection portion that maintains functional effectiveness across different orientations, allowing the asymmetric structure to prevent busbar plate deformation regardless of how the terminal is rotated during installation
Solution Approach 2:
Instead of requiring the pressing portion to point in a specific direction (upwards), the design allows the pressing portion to function effectively in any direction, inverting the conventional approach where orientation control is needed to achieve proper deformation prevention
3Ease of operation
If the wire and pressing portion protrude from the battery pack case, then the wire connection is accessible, but the overall external size of the battery pack increases reducing energy density
Solution Approach 1:
The ring terminal is designed to be nested within the battery pack case, with the pressing portion and wire connection features contained inside the case boundaries, similar to how nested dolls fit one inside another, eliminating external protrusions while maintaining internal functionality
Solution Approach 2:
The wire connection and pressing features are repositioned from external protrusions to internal components, changing the spatial dimension from outside-the-case to inside-the-case, thereby reducing external dimensions while preserving connection functionality
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
This design enhances processability, improves coupling force, reduces pack size, and increases energy density by ensuring flat contact surfaces and preventing the ring terminal from protruding, thus simplifying manufacturing and reducing external impact risks.
Implementation Method 1
Coupling may be performed using a rivet as a method of shortening the coupling process time and securing high coupling force
Implementation Method 2
a pressing portion configured to press the wire
Implementation Method 3
The end 112 of an external coupling portion of a busbar plate 110 is pressed by a connection portion 122 located between the ring portion 121 and the pressing portion 123, the connection portion protruding downwards. As a result, the end 112 of the external coupling portion is deformed so as to be bent downwards
Data Source
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AI summary
The present invention relates to a battery pack including a plurality of battery cells coupled to a busbar plate and a battery pack case configured to receive the plurality of battery cells, wherein an external coupling portion of the busbar plate is disposed at the outer surface of the battery pack case so as to be exposed therefrom, and the external coupling portion is coupled to a ring terminal by fastening using a rivet without being deformed. The external coupling portion of the busbar plate is deformed such that opposite surfaces of the ring terminal can be coupled to the busbar plate.