Battery Sampling Plate Assembly for Compact Module Wiring
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Solution Overview
Problem
Battery modules have low production efficiency, poor manufacturability, and low volumetric energy density due to complex manufacturing processes and the need for numerous components, particularly in the electrical connections and cell fixing methods.
Innovation Solution
The use of a battery sampling assembly with integrated conductive sheets on sampling plates, replacing traditional wiring harnesses, and a cell fixing rack with glue obstructing sleeves to prevent overflow, allowing for reduced component count, simplified assembly, and increased volumetric energy density through direct welding and glue filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional wiring harness isolation and sampling wiring harnesses are used, then electrical connections can be established, but the volume of the battery module increases and component count increases
Solution Approach 1:
The patent combines the isolation plate and sampling wiring harness into an integrated sampling assembly. The conductive sheets are directly welded to the sampling plate, eliminating the need for separate wiring harnesses and isolation components. This merging of functions reduces both the volume of the battery module and the total component count while maintaining electrical connection capabilities.
2Productivity
If traditional wiring harnesses and isolation components are used, then electrical connections are established, but manual work increases and production efficiency decreases
Solution Approach 1:
The patent replaces the complex mechanical assembly of traditional wiring harnesses with a simplified welding process. The conductive sheets are directly welded to the sampling plate using welding technology, which can be more easily automated than the manual assembly of wiring harnesses. This substitution of welding for mechanical assembly reduces manual work requirements and improves production efficiency.
3Ease of manufacture
If conductive sheets are directly welded to sampling plates, then assembly is simplified and production efficiency improves, but welding precision and connection reliability must be maintained
Solution Approach 1:
The patent specifies particular parameters for the welding process including welding method (e.g., laser welding, resistance welding), welding current, welding time, and weld seam depth to ensure reliable electrical connections. By controlling these welding parameters, the patent achieves both simplified assembly and maintained manufacturing precision, resolving the contradiction between ease of manufacture and welding precision.
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 approach reduces the volume of the battery module, increases production efficiency, and enhances manufacturability by minimizing manual work and component usage while maintaining reliable electrical connections.
Implementation Method 1
the conductive sheets are directly welded to the surfaces of the sampling plates
Implementation Method 2
a cell fixing rack with glue obstructing sleeves to prevent overflow
Data Source
AI summary
A battery sampling assembly, a cell fixing rack, a battery module, and an electric apparatus are provided. The battery sampling assembly includes a first sampling plate and a second sampling plate. A surface of the first sampling plate is provided with at least one first conductive sheet at one end and a second conductive sheet at another end, and a surface of the second sampling plate is provided with at least one third conductive sheet. In this application, the two sampling plates are separately provided with the conductive sheets, and the conductive sheets are directly welded to the surfaces of the sampling plates. Such design reduces space occupancy and allows for replacement for both wiring harness isolation and sampling wiring harnesses, so that relatively less components are used, and thus the volume of the entire module is reduced, and volumetric energy density of the battery module is increased.