Pouch Cell Battery Pack Tab Collector for Low-Complexity Assembly
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Solution Overview
Problem
Existing battery packs with multiple cells require complex connections and monitoring systems, leading to increased component count and volume, which in turn raises costs and complicates the assembly process.
Innovation Solution
A battery pack design featuring a stamped metal tab collection element with specific receiving and affixing sections for battery cell tabs, integrated into a plastic housing, allows for efficient connection and monitoring of individual cells through a flexible circuit, reducing the need for additional components and post-processing glue, while improving vibration performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional separate components and post-processing glue are used for connecting battery cell tabs, then reliable electrical connections can be achieved, but component count and volume increase, raising costs and complicating assembly
Solution Approach 1:
The patent combines the tab connection function and electrical connection function into a single integrated tab connector component. This connector includes conductive elements that directly connect battery cell tabs without requiring separate glue application steps or additional components, thereby reducing component count while maintaining connection reliability through the integrated design
Solution Approach 2:
The tab connector is designed to perform multiple functions simultaneously: it provides mechanical support for battery cell tabs, establishes electrical connections between cells, and enables voltage monitoring through integrated contact elements. This multi-functionality eliminates the need for separate components for each function, reducing overall device complexity
2Reliability
If more components and post-processing glue are used for tab connections, then connection reliability improves, but manufacturing cost increases
Solution Approach 1:
The patent merges multiple functions (mechanical support, electrical connection, voltage monitoring) into a single tab connector component that can be manufactured as one piece. This eliminates the need for multiple separate components and post-processing glue application, reducing manufacturing steps and associated costs while maintaining connection reliability through the integrated design
3Reliability
If traditional tab connection methods are used, then electrical connections can be established, but overall battery pack volume increases
Solution Approach 1:
The patent integrates the tab connector directly into the battery pack housing structure, combining the connection function with the structural housing. This integration eliminates the need for separate connection components and reduces the space required for tab connections, thereby reducing overall battery pack volume while maintaining electrical connection capability
Solution Approach 2:
The tab connector is nested within the battery pack housing structure, with conductive elements positioned to connect tabs while being contained within the existing housing volume. This nesting approach allows the connection system to utilize the existing structural space efficiently, minimizing additional volume requirements
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 simplifies the assembly of battery packs by reducing the component count and volume, enhancing vibration performance, and minimizing post-processing requirements, while maintaining effective electrical connections and monitoring capabilities.
Implementation Method 1
a tab collection element, formed of a stamped metal and within a plastic housing, including a battery cell tab receiving and affixing portion
Implementation Method 2
receiving and affixing sections for receiving and coupling the battery cell tabs to the tab collection element and to each other
Implementation Method 3
the receiving and affixing sections including a first section type for receiving and affixing a single battery cell tab and a second section type for receiving and affixing two battery cell tabs
Data Source
AI summary
The present disclosure is directed to a battery pack and a method of forming a battery pack. The battery pack may include a collection element for receiving and connection battery cell tabs of a plurality of pouch cell type battery cells. The collection element may be made from a single, stamped piece of metal. The battery pack may include a plastic housing that is injection molded about the metal stamped collection element. Such a configuration reduces the number of component parts and simplifies the manufacturing process.