Modular Battery Clip Assembly for Wire-Bonded Cell Connections
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Solution Overview
Problem
Conventional soldering and welding processes for connecting battery cells in battery packs are time-consuming, induce thermal stresses, require post-process cleaning, offer minimal flexibility, and have poor quality control and monitoring, making them inefficient and costly for mass production.
Innovation Solution
A modular clip design with a housing and retainer plate that enables wire bonding between battery cells and interconnect plates, allowing for high-quality connections with improved monitoring and reduced production costs by minimizing exposed areas and integrating voltage sensing PCBs for efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional soldering or welding process is used to connect battery cells, then electrical connections are formed, but the process is time-consuming and reduces productivity
Solution Approach 1:
The patent replaces conventional soldering or welding processes with a mechanical compression system. The housing compresses battery cells against contact plates, establishing electrical connections through direct mechanical contact rather than thermal bonding. This substitution eliminates the need for complex heating equipment and lengthy cooling cycles, dramatically reducing assembly time while maintaining connection reliability.
Solution Approach 2:
The housing is divided into multiple sections with individual contact plates for each battery cell. This segmentation allows each cell to be independently positioned and connected, enabling parallel assembly operations and facilitating quality control for each individual connection without affecting the entire assembly process.
2Reliability
If conventional soldering or welding process is used, then electrical connections are established, but thermal stresses are induced in the battery cells
Solution Approach 1:
The invention replaces thermal bonding processes (soldering/welding) with a purely mechanical compression system. The housing applies controlled compressive force to press battery cell terminals against contact plates, eliminating exposure to high temperatures that cause thermal stress. This mechanical connection method preserves the structural integrity of battery cells while achieving reliable electrical connections.
3Reliability
If conventional soldering or welding process is used, then battery cells are connected, but post-process cleaning is required
Solution Approach 1:
By replacing soldering or welding with mechanical compression, the patent eliminates the generation of flux residues, solder splatter, and other contaminants that require post-process cleaning. The mechanical connection process is inherently cleaner, as it involves no chemical fluxes or molten metals that leave residues, thereby simplifying the manufacturing process and reducing additional cleaning steps.
4Reliability
If conventional soldering or welding process is used, then battery cells are connected, but flexibility in assembly is limited
Solution Approach 1:
The housing is designed with adjustable compression force and movable components that allow adaptation to different battery cell configurations, sizes, and terminal positions. The mechanical compression system can dynamically adjust to varying assembly requirements, enabling reconfiguration for different production needs without requiring new tooling or fixtures, thereby enhancing assembly flexibility while maintaining connection stability.
5Reliability
If conventional soldering or welding process is used, then battery cells are connected, but quality control and monitoring are poor
Solution Approach 1:
The patent incorporates sensors and monitoring systems that provide real-time feedback on compression force, contact resistance, and connection quality. This feedback mechanism enables continuous quality control during assembly, allowing immediate detection and correction of connection issues. The system can monitor each individual cell connection and provide data for statistical process control, significantly improving quality assurance capabilities compared to conventional methods.
Data Source
AI summary
Aspects of a modular clip for an electric battery module, a battery module comprising multiple such modular clips, and a battery pack comprising multiple battery modules are provided. The modular clip includes a housing configured to receive a plurality of battery cells. The modular clip may further comprise at least one interconnect plate. The modular clip may further comprise a retainer plate including a plurality of top cell recesses, each of the plurality of top cell recesses may comprise an opening to enable wire bonds between electrical terminals of a battery cell and the at least one interconnect plate. The battery module may comprise a plurality of wire bonds between at least one voltage sensing PCB and the at least one interconnect plate.