Direct Pouch Cell Tab Joining for High-Density Battery Packs
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Solution Overview
Problem
Existing methods for electrically connecting battery cells in traction batteries, particularly pouch-style cells, often rely on busbars, which can limit packaging density and efficiency.
Innovation Solution
A method involving the folding and welding of tab terminals from adjacent battery cells, followed by compression and insulation, eliminates the need for busbars, allowing for direct electrical connection and increased packing density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If busbars are used to electrically connect battery cells, then electrical connectivity is ensured, but packaging density is reduced
Solution Approach 1:
The patent extracts and eliminates the busbar component from the battery assembly by directly welding tab terminals from adjacent battery cells together, thereby removing the unnecessary intermediary element that occupied space and reduced packaging density while maintaining electrical connectivity
Solution Approach 2:
The patent merges the electrical connection function directly into the tab terminal structure by welding adjacent tabs together, combining the functions of electrical connection and structural support into a single integrated solution that eliminates the need for separate busbars
2Strength
If tab terminals are folded and compressed during joining, then electrical connection strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by folding the tab terminals into the desired configuration before the welding process, ensuring proper alignment and contact between tabs prior to joining, which simplifies the welding operation and ensures strong electrical connections
Solution Approach 2:
The patent utilizes parameter changes by applying compression force during the joining process to increase contact pressure between tab terminals, thereby improving weld quality and electrical connection strength through controlled mechanical parameter adjustment
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 approach enhances packaging density and efficiency by eliminating busbars, enabling a higher density battery system with improved electrical connectivity.
Implementation Method 1
the joining includes welding the first tab terminal to the second tab terminal
Implementation Method 2
after the joining, compressing the first tab terminal and the second tab terminal
Data Source
AI summary
A method includes electrically connecting a first battery cell to a second battery cell by joining a first tab terminal of the first battery cell to a second tab terminal of the second battery cell. The method further includes compressing the first tab terminal and the second tab terminal after the joining. A battery assembly includes a first tab terminal extending from a first housing of a first battery cell, and a second tab terminal extending from a second housing of a second battery cell. The second tab terminal is connected directly to the first tab terminal. The method further includes an insulating layer that encloses the first and second tab terminals against the first and second housings.