Battery Tab Terminal Clasp Retention for Reliable Pack Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery pack terminal retention systems in traction battery packs face challenges in securely and efficiently connecting and holding tab terminals of lithium-ion battery cells, which can lead to unreliable electrical connections and potential structural integrity issues.
Innovation Solution
A battery pack terminal retention system that includes a clasp engaging a cross-member, with the clasp sandwiching tab terminals against the cross-member or sense lead, and using welds to electrically connect them, while the clasp applies a clamp load and provides access for welding through an aperture, enhancing structural integrity and electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional terminal retention systems are used, then the structure is simple, but the electrical connection reliability deteriorates
Solution Approach 1:
The clasp integrates multiple functions: it mechanically retains the tab terminals, applies clamp load for electrical connection, and provides structural support. By combining retention, electrical connection, and support functions into a single component, the system achieves reliable electrical connections without proportionally increasing overall system complexity
Solution Approach 2:
The clasp serves as a multi-functional element that simultaneously acts as a mechanical retainer, an electrical connector through weld integration, and a structural support member. This multi-functionality resolves the contradiction by delivering reliable electrical connections while minimizing the number of separate components needed
2Strength
If clamp load is applied to secure terminals, then the structural integrity is improved, but the manufacturing complexity increases
Solution Approach 1:
The clasp is pre-configured with integrated welding features and aperture structures that enable subsequent welding operations. By preparing the clasp design in advance with these built-in features, the application of clamp load and the welding process become more straightforward, reducing manufacturing complexity while maintaining structural integrity
Solution Approach 2:
The welding aperture is integrated within the clasp structure, allowing welding tools to access the terminal connection point through the clasp itself. This nested design enables the clasp to provide both mechanical retention and electrical connection functionality without requiring separate manufacturing steps for structural and electrical components
3Reliability
If welds are used to electrically connect terminals, then the electrical connectivity is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The clasp design incorporates self-aligning features and integrated welding apertures that guide the welding process. The structure itself provides the positioning necessary for accurate weld placement, reducing the precision requirements for external welding operations while ensuring reliable electrical connectivity
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 system effectively secures and electrically connects tab terminals, ensuring reliable connections and structural integrity by applying a clamp load and facilitating welding, thereby enhancing the performance and safety of the battery pack.
Implementation Method 1
the clasp applies a clamp load to the plurality of tab terminals when holding the plurality of tab terminals
Implementation Method 2
a plurality of welds that electrically connect together the plurality of tab terminals
Data Source
AI summary
A battery pack terminal retention system includes a clasp configured to hold tab terminals as the tab terminals are electrically connected together. A battery pack terminal retention method includes holding terminals together using a clasp; and electrically connecting together the plurality of terminals during the holding. The terminals can be tab terminals that are electrically connected together using welds.