Battery Sampling Assembly for Butt-Welded Cell Gaps
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery modules with butt-welded poles face challenges in voltage sampling due to limited space and complex assembly processes, including welding and sampling complications, which hinder efficient production and automation.
Innovation Solution
A battery sampling device with a conductive component, sampling component, and bearing component that allows for weld-free electrical connection by inserting into the gap between butt-welded battery cells, utilizing resilient contacts and limiting components to ensure reliable and efficient installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sampling component is welded to the connecting strips, then reliable electrical connection is achieved, but the assembly process becomes complex and production efficiency is reduced
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical pressing system. The pressing component applies mechanical force to compress the conductive component against the electrode terminal, achieving electrical connection without welding. This substitution eliminates the complex welding steps while maintaining reliable electrical connection through elastic contact pressure.
Solution Approach 2:
The patent introduces a pressing component as an intermediary element between the conductive component and the electrode terminal. This pressing component mediates the connection by providing elastic pressure, ensuring stable electrical contact without requiring direct welding between the conductive component and electrode terminal, thus simplifying the assembly process.
2Reliability
If the sampling component is welded to the connecting strips, then electrical connection is established, but production efficiency is reduced
Solution Approach 1:
The patent replaces the welding process with a mechanical pressing system that can be rapidly applied during assembly. The pressing component's elastic deformation allows for quick installation and removal without thermal processing, significantly improving production efficiency while maintaining reliable electrical connection through sustained contact pressure.
Solution Approach 2:
The conductive component is pre-formed with elastic deformation characteristics before assembly. This preliminary preparation allows the component to be quickly installed and automatically establish reliable electrical connection upon compression, eliminating the need for time-consuming welding operations during the assembly process.
3Strength
If butt welding of poles is used, then battery cell connection is achieved, but voltage sampling space becomes limited and welding/sampling cannot be performed
Solution Approach 1:
The patent transitions the sampling operation from a two-dimensional surface operation (welding on the pole end face) to a three-dimensional volume operation (inserting the pressing component into the gap between cells). This dimensional change provides sufficient space for the pressing component and conductive component to achieve reliable electrical connection without interfering with the butt welding of the poles.
Solution Approach 2:
The patent separates the connection function (performed by butt welding of poles) from the sampling function (performed by the pressing component and conductive component). This segmentation allows each function to be optimized independently: the butt welding provides strong mechanical connection, while the pressing component provides flexible electrical connection for sampling without space constraints.
4Reliability
If transfer welding and sampling are used, then electrical connection is achieved, but the structure becomes complicated and manufacturing is difficult
Solution Approach 1:
The patent merges the electrical connection function and the sampling function into a single integrated pressing component assembly. The pressing component simultaneously provides mechanical pressure for connection and houses the conductive component for sampling, eliminating the need for separate transfer welding and sampling operations, thus simplifying manufacturing.
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
The solution simplifies assembly, ensures reliable electrical connections, and enables automatic installation, improving production efficiency and preventing disconnection due to vibrations.
Implementation Method 1
the conductive component has a certain deformation displacement characteristic to be further adapted to the dimension of the battery after cyclic expansion
Implementation Method 2
the conductive component abuts against a side surface of the pole and the sampling component, so as to realize an electric connection among the pole, the conductive component and the sampling component
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present application relates to the technical field of batteries and particularly relates to a battery sampling device, a battery, and an electricity consumption device. The battery sampling device includes a conductive component, a sampling component and a bearing component, where the conductive component is in contact with a pole and is electrically connected to the pole; the sampling component is electrically connected to the conductive component and is configured to transmit or process electrical parameters acquired by the conductive component; and the bearing component is configured to bear the conductive component and the sampling component and to be adapted to being inserted into a gap between two battery cells with end surfaces of the pole welded with each other, where the conductive component abuts against a side surface of the pole and the sampling component, so as to realize an electric connection among the pole, the conductive component and the sampling component. The above structure achieves the weld-free electric connection by way of inserted installation of the sampling component and the battery cells, so that the processing difficulty is reduced. Automatic installation may further be smoothly achieved, so that the production efficiency is improved.