Bus Bar Holder Groove Structure for Battery Pack Spatter Containment
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Solution Overview
Problem
The existing battery pack designs face issues with spatter generation during the welding process of bus bars and electrodes, leading to quality degradation and potential short-circuits due to spatter accumulation, which current methods like high-pressure air or suction fail to fully prevent.
Innovation Solution
The battery pack incorporates a bus bar holder with a support and receiving portion that includes a groove system to contain and direct spatters away from the battery cells, using a configuration of barriers and grooves to prevent spatter introduction and facilitate easy removal using blowing or suction devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If high-pressure air or suction is used to remove spatter, then spatter removal effectiveness is improved, but some spatter remains and can still cause short-circuits or insulation failures
Solution Approach 1:
The invention converts the harmful spatter into a contained element by directing it into a receiving groove. The groove system captures spatter that would otherwise cause short-circuits, transforming the harmful scattered metal particles into a controlled, contained state that can be safely managed without compromising insulation reliability
Solution Approach 2:
The receiving groove acts as an intermediary structure between the welding region and the battery cell insulation. It intercepts and contains spatter before it can reach critical insulation areas, serving as a protective mediator that prevents direct contact between spatter and insulation components
2Reliability
If barriers are added to prevent spatter introduction, then spatter containment is improved, but device complexity increases
Solution Approach 1:
The invention merges the support structure and spatter containment function into a single integrated receiving groove system. Rather than adding separate barriers and containment structures, the groove is formed as part of the existing support architecture, achieving spatter containment without proportionally increasing device complexity
Solution Approach 2:
The receiving groove serves multiple functions: it provides structural support, directs spatter away from critical areas, and contains captured spatter. This multi-functionality reduces the need for additional specialized components, thereby limiting the increase in device complexity while maintaining effective spatter containment
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 design effectively reduces spatter introduction into the battery pack, enhancing the quality and reliability by containing spatters within the groove system and allowing for easy removal, thus preventing insulation failures and short-circuits.
Implementation Method 1
a receiving portion including a receiving groove extending from the support and communicating with the opening
Data Source
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AI summary
A battery pack includes: a plurality of battery cells comprising one or more electrodes; one or more bus bars comprising one or more connecting portions connected to the one or more electrodes; a pair of side plates at opposite sides of the plurality of battery cells; and a bus bar holder including: an opening corresponding to each of the electrodes; a support comprising a support groove into which the side plate is inserted; and a receiving portion comprising a receiving groove extending from the support and communicating with the opening.