Foldable Plate Battery Bus Bar Assembly
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Solution Overview
Problem
High voltage vehicle batteries face complexities in assembly due to unstable conducting resistance, micro gap management, and increased component count, leading to potential fire and explosion risks, as well as increased facility investment and complexity in managing various cell shapes.
Innovation Solution
A high voltage battery design featuring foldable plates with integrated bus bars and connectors that eliminate the need for welding, allowing for simplified assembly and reduced component count, with a clip and presser system to manage cell expansion and prevent swelling-related issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cell lead parts are welded by laser beam, then electrical connection is achieved, but conducting resistance becomes unstable and micro gap management becomes difficult
Solution Approach 1:
The patent replaces the laser welding process (thermal/mechanical system) with a mechanical pressing system. The presser applies compressive force to bring the cell lead parts into direct contact, eliminating the need for welding and its associated micro gap issues. This mechanical substitution achieves stable electrical connection without the complexity of welding process control.
2Reliability
If dedicated jig space is secured for welding, then welding defects are managed, but battery module size increases
Solution Approach 1:
The patent extracts and removes the welding process entirely from the battery assembly system. By eliminating welding, the dedicated jig space required for welding operations is no longer needed, thereby reducing the battery module size while maintaining defect management through the alternative mechanical pressing connection method.
3Reliability
If cell swelling is physically blocked, then swelling is prevented, but current blocking structure becomes complicated and fire risk increases
Solution Approach 1:
The patent replaces complex physical blocking structures with a simple elastic pressing mechanism. The presser utilizes elastic deformation to maintain continuous contact pressure on the cell lead parts, preventing swelling through sustained mechanical force rather than complex blocking structures. This simplification also eliminates the fire risk associated with delayed reaction to swelling.
4Reliability
If separate cell sensing structure is used, then cell monitoring is achieved, but assembling process becomes complicated
Solution Approach 1:
The patent merges the sensing function into the existing presser structure. The presser not only applies mechanical force to prevent swelling but also serves as the sensing element that detects cell state. This integration eliminates separate sensing components and simplifies the assembling process while maintaining cell monitoring capability.
5Reliability
If welding process is used for various cell shapes, then electrical connection is achieved, but line facility investment increases
Solution Approach 1:
The patent creates a universal mechanical pressing system that can accommodate various cell shapes. The presser applies distributed contact pressure that adapts to different geometries, eliminating the need for welding process adjustments. This multi-functional approach allows the same assembly line to handle diverse cell types without additional facility investment.
Data Source
AI summary
A high voltage battery for a vehicle includes a first plate, a second plate, and a third plate coupled to be folded with each other and have cell insertion spaces formed therebetween. A bus bar includes a first lead which is inserted into a side boundary of the first plate and the second plate to contact a tab of a cell, a second lead which is inserted into a side boundary of the second plate and the third plate to contact a tab of another cell, and a connector which connects the lead to the second lead.