Battery Pack Bus Bar Holder Structure for Welding Spatter Containment
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Solution Overview
Problem
The existing battery pack designs face quality degradation due to spatter generated during the welding process between the bus bar and battery cells, which can lead to short-circuits and insulation failures.
Innovation Solution
The battery pack incorporates a bus bar holder with a support and receiving portion that includes a longitudinal groove to contain and redirect spatter, preventing it from entering the battery cell and facilitating easy removal using blowing or suction devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If high-pressure air or negative pressure is used to blow away spatter during welding, then spatter removal is improved, but some spatter remains in the battery pack causing quality degradation
Solution Approach 1:
A receiving portion is introduced as an intermediary structure between the welding region and the battery cell. This receiving portion includes a receiving groove that captures and contains spatter, preventing it from reaching critical areas. The bent portion of the side plate also serves as an intermediary barrier to redirect spatter into the receiving groove.
Solution Approach 2:
The harmful spatter is extracted from the main battery pack structure by directing it into a dedicated receiving groove. This groove acts as a separate containment zone, isolating the spatter from the functional components and allowing for its removal without affecting battery pack quality.
2Ease of manufacture
If the bus bar holder structure is simplified, then manufacturing is easier, but spatter containment and redirection capabilities are reduced
Solution Approach 1:
The bus bar holder is segmented into distinct functional portions: a support portion for structural stability and a receiving portion with a receiving groove for spatter containment. The side plate is also segmented with a bent portion that redirects spatter. This segmentation allows each component to be optimized for its specific function while maintaining overall manufacturing simplicity.
Solution Approach 2:
The receiving portion is specifically designed with a receiving groove at the location where spatter accumulation is most problematic. The bent portion of the side plate is positioned to redirect spatter into this groove. This local quality enhancement focuses spatter management resources only where needed, rather than complicating the entire structure.
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 effectively reduces spatter introduction into the battery pack, enhancing the quality and reliability by preventing short-circuits and insulation failures, and allowing for efficient spatter removal.
Implementation Method 1
a receiving portion including a receiving groove extending from the support and communicating with the opening
Data Source
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.