Battery Module Temperature Tab with Elastic Press Contact
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Solution Overview
Problem
Welding defects and associated costs are prevalent in connecting temperature sensors to battery cells in rechargeable battery modules, leading to potential deformation and foreign particle generation.
Innovation Solution
A temperature sensor is connected between a flexible printed circuit and a battery cell using a busbar holder with an elastic member to elastically pressurize a cell contact portion, eliminating the need for welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to connect the nickel tab to the battery cell, then the temperature sensor can be connected to the battery cell, but welding defects such as deformation and foreign particle generation occur
Solution Approach 1:
The patent replaces the welding process (thermal/chemical system) with a mechanical pressing system consisting of a pressing member that applies elastic force to press the nickel tab against the battery cell. This mechanical substitution eliminates welding defects such as deformation and foreign particle generation while maintaining reliable electrical connection between the temperature sensor and battery cell.
Solution Approach 2:
The patent introduces a pressing member as an intermediary component between the nickel tab and the battery cell. This pressing member transmits elastic force to maintain contact pressure without direct welding, thereby mediating the connection process to avoid harmful welding effects while ensuring stable electrical connection.
2Reliability
If welding is used to connect the nickel tab to the battery cell, then the temperature sensor connection is established, but process cost and quality management cost increase
Solution Approach 1:
The patent replaces the expensive welding process with a simpler mechanical pressing operation. The pressing member applies elastic force through elastic deformation to maintain contact, eliminating the need for welding equipment, skilled welders, and complex quality control procedures, thereby significantly reducing both process cost and quality management cost.
Solution Approach 2:
The pressing member is designed as a simple elastic component that can be easily manufactured and replaced if needed. This simple component performs the connection function without requiring expensive welding equipment or complex processing, making the overall manufacturing process more cost-effective.
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 method stabilizes the connection, prevents welding defects, and reduces costs by eliminating process and quality management expenses.
Implementation Method 1
an elastic member coupled to the cell contact portion and configured to elastically pressurize the cell contact portion onto the one of the battery cells
Data Source
AI summary
A rechargeable battery module includes: a busbar holder configured to cover a plurality of battery cells; a flexible printed circuit (FPC) configured to transmit a signal corresponding to a detected temperature of at least one of the battery cells from a temperature sensor mounted on the busbar holder; a temperature sensing tab including a sensor connection portion at a first side that is connected to the temperature sensor and a cell contact portion at a second side that is coupled to the busbar holder and in contact with the one of the battery cells; and an elastic member coupled to the cell contact portion and configured to elastically pressurize the cell contact portion onto the one of the battery cells.