Battery Cell Tab Welding Through Cross-Member Openings

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Solution Overview

Problem

Existing traction battery packs face challenges in efficiently electrically connecting groups of battery cells, which can affect the structural integrity and thermal management of the battery pack.

Innovation Solution

The traction battery pack incorporates a cell stack configuration with cell tab terminals of a common length that extend through cross-member assembly openings, are bent, and welded together against a backing tab, enhancing electrical connectivity and structural integration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If battery cells are electrically connected using traditional connection methods, then electrical connectivity is achieved, but the structural integrity and manufacturing complexity are compromised

Engineering Contradiction:

Improvestructural integrityVSAvoidconnection complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the electrical connection function with the structural support function by integrating battery cell tabs directly into the cross-member assembly. The tabs extend through openings in the cross-member and are welded to form both electrical connections and structural joints, eliminating the need for separate connection components and reducing overall device complexity while improving structural integrity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cross-member assembly serves multiple functions: it provides structural support for the battery cells, facilitates electrical connection through integrated tabs, and enables thermal management pathways. The tabs themselves serve dual purposes as both electrical conductors and structural bonding elements, reducing the number of separate components needed.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If battery cell tab terminals have varying lengths, then adaptability to different cell configurations is improved, but manufacturing precision and welding reliability deteriorate

Engineering Contradiction:

Improvecell configuration adaptabilityVSAvoidtab terminal length consistency

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent applies local quality by providing different tab length configurations in different locations within the battery assembly. First and second tabs extend beyond a first opening while third and fourth tabs extend beyond a second opening, with each location optimized for its specific cell configuration requirements. This allows adaptability to different cell arrangements while maintaining consistent manufacturing tolerances within each localized welding area.

Inventive Principle:

Principle #3Local quality

3Reliability

If cell tab terminals are directly welded to cross-member assembly, then electrical connectivity and structural integrity are improved, but manufacturing complexity increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidassembly manufacturing ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by pre-forming the tabs with extended portions that protrude through the cross-member openings before the welding operation. This pre-positioning ensures proper alignment and reduces the complexity of the welding process, as the tabs are already in their final positions and orientations, requiring only welding rather than complex positioning and alignment during assembly.

Inventive Principle:

Principle #10Preliminary action

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 configuration simplifies the electrical connection of battery cells, improves the structural integrity of the battery pack, and facilitates effective thermal management by compartmentalizing the cell stack with a structural thermal barrier assembly.

Implementation Method 1

a first weld bead joins the tip portions of the first and second cell tab terminals, and a second weld bead joins the tip portions of the third and fourth cell tab terminals

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS20250192377A1Traction battery packs with battery cell tab terminals of a common length for direct welding

Publication Date: 2025.06.12 FORD GLOBAL TECH LLC

AI summary

Techniques are provided for electrically connecting groups of battery cells within a traction battery pack. The battery cells within each groping may include cell tab terminals of a common length for direct welding relative to a cross-member assembly. Groups of cell tab terminals may be received through cell tab openings of the cross-member assembly and then bent into place relative to a backing tab for welding. The cross-member assembly may include various lead-in and bending features that facilitate cell tab terminal bending and welding.