Battery Sampling Circuit Board Hook Assembly Connection
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Solution Overview
Problem
Traditional harness isolation boards in battery modules face challenges in efficient and cost-effective production, with complex brazing and riveting processes leading to unstable connections between the main board and sampling terminals, which can result in increased contact resistance.
Innovation Solution
A sampling circuit board design featuring a main board with electrical connection areas and sampling terminals connected via a connection member with a hook assembly, which laminates and attaches the terminals and connection areas, replacing traditional soldering and riveting processes to ensure a stable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If brazing process is used to connect sampling terminals to main board, then connection strength is improved, but manufacturing complexity and connection area increase
Solution Approach 1:
The patent replaces the brazing process (thermal/chemical connection) with a mechanical pressing connection system. The pressing assembly applies mechanical force to press the sampling terminal against the main board, creating a stable electrical connection without requiring complex brazing equipment or processes. This substitution simplifies manufacturing while maintaining connection reliability.
2Reliability
If riveting combined with dispensing process is used, then connection stability is improved, but structural adhesive penetration increases contact resistance
Solution Approach 1:
The patent extracts and removes the dispensing process (adhesive application) from the connection system. By using only mechanical pressing without any adhesive, the patent eliminates the problem of adhesive penetration between electrical connection surfaces that would increase contact resistance. The pressing assembly achieves stable connection through pure mechanical force, ensuring low and consistent contact resistance.
3Reliability
If traditional harness isolation board is used, then voltage and temperature sampling is achieved, but production efficiency and cost-effectiveness deteriorate
Solution Approach 1:
The patent replaces the traditional harness isolation board structure with a simplified pressing connection system. This mechanical substitution enables automated production through efficient pressing operations, significantly improving production efficiency and cost-effectiveness while maintaining the voltage and temperature sampling functions.
Solution Approach 2:
The patent segments the connection function into a dedicated pressing assembly that can be independently optimized for automated manufacturing. This segmentation allows the pressing process to be decoupled from other manufacturing steps, enabling higher production efficiency and better cost-effectiveness while preserving the sampling functionality.
Data Source
AI summary
A sampling circuit board for a battery module includes a main board including a plurality of electrical connection areas, and a plurality of sampling terminals respectively electrically connected to the plurality of the electrical connection areas. An end of each of the sampling terminals extends away from the main board, and each of the sampling terminals connected to one of the electrical connection areas of the main board via a connection member. The connection member includes a main body and a hook assembly provided on the main body, and the hook assembly stacks and bonds one of the sampling terminals and one of the electrical connection areas of the main board.