Battery Pack Tab Clip Assembly for Fast Reliable Connections

The patent replaces traditional mechanical connection methods (welding or staking) with a purely mechanical clip-based system. The clip features resilient arms that apply continuous contact force to secure cell tabs to high voltage terminals, eliminating the need for thermal or heavy mechanical fastening processes. This substitution dramatically reduces assembly time while maintaining reliable electrical connection through sustained mechanical contact.

The clip assembly is designed to be self-aligning and self-securing. The resilient arms automatically adjust to accommodate variations in cell tab positioning, and the clip structure guides proper alignment during installation. This self-service mechanism eliminates the need for complex multi-step assembly procedures or highly skilled operators, achieving precise connections through inherent design features rather than process complexity.

The clip is designed as a multi-functional component that simultaneously provides mechanical securing, electrical connectivity, and thermal management. The conductive material of the clip ensures efficient electrical current flow between cell tabs and high voltage terminals. Additionally, the thermal conductivity of the clip helps dissipate heat generated during battery operation, while the resilient arms maintain consistent mechanical contact force. This universal design achieves multiple functions through a single integrated component.