Insulated Metal Sampling Sheet Assembly for Battery Pack Connections
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Solution Overview
Problem
Existing battery cell transfer modes, such as wire harness and flexible circuit board transfer, are complex in structure, have low connection efficiency, and high costs, with risks of short circuits and missed connections.
Innovation Solution
A battery sampling assembly using metal sampling sheets with insulating films, where each sheet has ends connected to busbars and circuit boards, simplifying the structure and ensuring reliable electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire harness transfer mode is used, then electrical connection can be achieved, but structure becomes complex and connection efficiency decreases
Solution Approach 1:
The patent extracts the essential function of electrical connection from the complex wire harness system and implements it through a simplified metal sampling sheet structure. The metal sampling sheet directly connects the battery cell terminal to the PCB, eliminating the need for complex wire harness assemblies while maintaining reliable electrical connection.
Solution Approach 2:
The patent uses a thin metal sampling sheet with insulating film coating to replace the bulky wire harness structure. The metal sampling sheet acts as a flexible conductor that can be easily installed while providing stable electrical connection, significantly reducing structural complexity.
2Reliability
If flexible circuit board transfer mode is used, then electrical connection can be achieved, but structure becomes complex and cost increases
Solution Approach 1:
The patent extracts the core electrical connection function from the complex flexible circuit board transfer mechanism and replaces it with a simple metal sampling sheet structure. This extraction eliminates unnecessary intermediate components and reduces both structural complexity and manufacturing cost.
Solution Approach 2:
The metal sampling sheet provides a cost-effective solution compared to flexible circuit boards. The simple metal sheet structure with insulating coating is cheaper to manufacture while providing equivalent electrical connection reliability, reducing overall system cost.
3Reliability
If wire harness or flexible circuit board is used, then electrical connection can be established, but connection efficiency decreases due to numerous components
Solution Approach 1:
The patent segments the electrical connection function into a single integrated metal sampling sheet component rather than using multiple wire harness or circuit board elements. This segmentation into one unified component streamlines the connection process and improves assembly efficiency.
Solution Approach 2:
The patent merges the conductor, insulator, and connector functions into a single metal sampling sheet assembly. By combining these previously separate components into one integrated structure, the patent eliminates the need for numerous separate parts and improves connection efficiency.
Data Source
AI summary
A battery sampling assembly and a battery pack are provided. The battery sampling assembly includes at least one metal sampling sheet and at least one insulating film. Each of the metal sampling sheet includes a body. A first end portion and a second end portion are arranged at two ends of the body. The first end portion is configured to be electrically connected with a busbar. The second end portion is configured to be electrically connected with a circuit board. The insulating film covers the body of the metal sampling sheet.