Force Generating Assembly for Weld-Free Battery Cell Connections
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Solution Overview
Problem
Conventional battery packs require labor-intensive and costly welding for electrical connections, reducing volumetric efficiency due to the need for bus bars and connectors.
Innovation Solution
A battery pack design featuring a force generating assembly that applies forces in orthogonal directions to create direct, weld-free electrical connections between electrochemical cells, utilizing a pressure plate and elastic members to ensure contact between terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to form electrical connections between cells and bus bars, then reliable electrical connections are achieved, but manufacturing complexity and cost increase, and volumetric efficiency decreases
Solution Approach 1:
The patent removes the welding process and bus bar system from the battery pack design. Instead of using traditional welded connections with bus bars, the invention extracts these components entirely and replaces them with a direct mechanical contact system where cell terminals are pressed together using spring-loaded contact elements, thereby eliminating manufacturing complexity while maintaining electrical connection reliability
Solution Approach 2:
The patent replaces the welding process (thermal/mechanical joining) with a purely mechanical contact system. Spring-loaded contact elements apply continuous mechanical pressure to maintain electrical contact between cell terminals, substituting the welding operation with a mechanical pressure-based connection system that is simpler to manufacture and more space-efficient
2Reliability
If welding and bus bar system are used for electrical connections, then reliable electrical connections are achieved, but the volumetric efficiency of the battery pack is reduced
Solution Approach 1:
The patent extracts and removes the bus bar system from the battery pack design. By eliminating the bus bars and their mounting structures, the invention recovers significant volume within the battery pack housing, allowing for higher cell density and improved volumetric efficiency while maintaining electrical connection functionality through direct terminal-to-terminal contact
Solution Approach 2:
The patent merges the electrical connection function directly into the cell terminal interface. Instead of using separate bus bars as intermediate connectors, the invention combines the electrical connection path directly between adjacent cell terminals, eliminating the need for additional connector components and reducing the overall volume required for electrical connections
3Reliability
If welding is used to connect cells and control devices, then reliable electrical connections are achieved, but manufacturing time and cost increase
Solution Approach 1:
The patent removes the welding operation from the manufacturing process entirely. By extracting the welding step and replacing it with mechanical assembly of spring-loaded contact elements, the invention eliminates the time-consuming welding process while maintaining reliable electrical connections, thereby significantly improving manufacturing efficiency and reducing production costs
Solution Approach 2:
The spring-loaded contact elements are designed to self-assemble and self-adjust during the manufacturing process. The springs automatically apply the necessary contact pressure when cells are positioned together, eliminating the need for complex welding equipment and skilled welding operations, thereby simplifying the manufacturing process and improving productivity
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 reduces manufacturing costs and increases volumetric efficiency by eliminating the need for welding and minimizing space occupied by electrical connectors.
Implementation Method 1
an elastic member that is disposed between the pressure plate and the battery pack housing. The elastic member is arranged to urge the pressure plate away from the battery pack housing
Implementation Method 2
The force generating assembly is configured to apply a first force to the array of electrochemical cells along a first direction and a second force to the array of electrochemical cells along a second direction
Data Source
AI summary
A battery pack includes a battery pack housing and an array of pouch cells disposed in the pack housing. The battery pack also includes a force generating assembly disposed in the battery pack housing. The force generating assembly is configured to apply a force to the array of cells along a first direction corresponding to a row of cells, and a force to the array of cells along a second direction corresponding to a column of cells. The forces result in a weld-free, direct electrical connection being formed between a first pair of adjacent cells within a row, and the second force results in a weld-free, direct electrical connection being formed between a second pair of adjacent cells within a column.