Battery Module Terminal Assembly Without Bus Bar Welding
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Solution Overview
Problem
Traditional battery module configurations require extensive welding of major bus bars and terminals, leading to high material costs and reduced energy density due to material compatibility constraints and bulkiness.
Innovation Solution
The battery module design features major terminals with a base and post, where the major bus bar wraps around the terminal without welding, using dissimilar materials and embedding the combined components in a plastic housing to enhance energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional welding methods are used to connect major bus bars and terminals, then electrical connectivity is established, but material costs increase and energy density decreases due to material compatibility constraints and bulkiness
Solution Approach 1:
The patent introduces a terminal as an intermediary component between the major bus bar and the electrochemical cell. This terminal includes a base that receives the bus bar and a post that connects to the cell, allowing dissimilar materials (e.g., aluminum bus bar with copper terminal) to be connected without welding. The intermediary terminal resolves the material compatibility constraints of traditional welding while maintaining reliable electrical connectivity.
Solution Approach 2:
The patent replaces the welding process (thermal/mechanical system) with a mechanical connection system. The bus bar is inserted through an opening in the terminal base and secured using mechanical means such as friction fit, interference fit, or mechanical fasteners. This substitution eliminates the need for welding, allowing dissimilar materials to be joined without material compatibility constraints and reducing the bulkiness associated with welded joints.
2Reliability
If traditional welding methods are used to connect major bus bars and terminals, then electrical connectivity is established, but device complexity increases due to extensive welding requirements
Solution Approach 1:
The patent replaces the complex welding process with a simpler mechanical connection system. The bus bar passes through an opening in the terminal base and is secured by mechanical means, eliminating the need for welding equipment, skilled welders, and complex welding procedures. This substitution significantly reduces device complexity while maintaining reliable electrical connectivity.
Solution Approach 2:
The terminal acts as an intermediary that simplifies the connection process. By providing a pre-formed connection interface with an opening and securing mechanism, the terminal mediates between the bus bar and the electrochemical cell, eliminating the need for complex welding operations and reducing overall device complexity.
3Quantity of substance
If dissimilar materials are used for major bus bar and terminal, then material cost decreases and energy density increases, but material compatibility for welding becomes problematic
Solution Approach 1:
The terminal serves as an intermediary that decouples the material selection of the bus bar from the material selection of the cell connection. This allows the bus bar to be made from cost-effective materials like aluminum while the terminal can be made from materials optimized for cell connection, without requiring welding between dissimilar materials. The mechanical connection through the terminal base enables this material flexibility.
Solution Approach 2:
By replacing welding with a mechanical connection system, the patent enables the use of dissimilar materials that would be incompatible for welding. The bus bar passes through the terminal base and is secured mechanically, allowing aluminum bus bars with copper terminals or other dissimilar material combinations without worrying about welding compatibility, thereby reducing material costs and increasing energy density.
Data Source
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AI summary
The present disclosure includes a battery module that includes an electrochemical cell having a minor terminal. The battery module also includes a major terminal electrically coupled to the electrochemical cell, wherein the major terminal includes a base and a post extending from the base. Further, the battery module includes an electrical path between the minor terminal of the electrochemical cell and the major terminal of the battery module. The electrical path includes a bus bar having an opening that receives the post of the major terminal and a pocket that retains the base of the major terminal.