Battery Wiring Unit With Movable Terminal for Lead Tolerance
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Solution Overview
Problem
The existing configuration of electrode leads in high-voltage battery packs for electric vehicles results in manufacturing tolerances that can lead to poor electrical connections due to incomplete contact between module terminals and electrode leads, especially in the front-rear direction, causing reliability issues.
Innovation Solution
A wiring unit with a terminal and protector design that allows the electrode leads to be joined in an overlapping manner, featuring a movable bent plate portion inserted into a recess, enabling reliable contact despite manufacturing tolerances, and includes a flexible piece for smooth insertion and locking to ensure stable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If electrode leads are bent and welded to connect adjacent battery cells, then the wiring unit can achieve electrical connection without additional bus bars, but manufacturing tolerance increases in the front-rear direction causing poor contact between module terminals and electrode leads
Solution Approach 1:
The terminal is designed with a movable bent plate portion that can dynamically adjust its position in the front-rear direction. The bent plate portion slides within a recess of the protector, allowing the terminal to automatically compensate for manufacturing tolerances and maintain full contact with the electrode leads during laser welding or other connection processes.
2Productivity
If laser welding is used to connect module terminals to electrode leads, then connection speed and automation are improved, but poor electrical connection occurs when manufacturing tolerance causes incomplete contact
Solution Approach 1:
The movable bent plate portion enables the terminal to dynamically adjust its position to ensure full contact with the electrode leads before laser welding begins, maintaining high connection quality while preserving the speed and automation benefits of laser welding processes.
Solution Approach 2:
The recess in the protector is designed with sufficient depth and dimensional tolerance to accommodate the bent plate portion's movement range, providing a cushioning effect that absorbs manufacturing tolerance variations and ensures reliable contact before the welding process starts.
Data Source
AI summary
A wiring unit has excellent reliability of electrical connection between a terminal and electrode leads. The wiring unit is mounted on a battery stack, which is formed by stacking a plurality of laminated batteries including electrode leads, and includes a joining portion for joining the electrode leads of the laminated batteries in a mutually overlapping manner, the wiring unit including: a terminal; an electric wire that is connected to the terminal; and a protector that holds the terminal and the electric wire, the terminal including: a main body portion; a connecting portion that is configured to extend from the main body portion and is oppositely connected, in a first direction, to the electrode leads forming the joining portion; and at least one bent plate portion that extends from the main body portion to the side of the laminated batteries in the first direction, and the protector including: a protector main body.