Pouch Cell Top Plate and Bus Bar Frame Assembly for Faster Joining

Solution Overview

Problem

The challenge in battery cell assembly is to improve productivity while ensuring efficient electrical connections and structural integrity.

Innovation Solution

A battery cell assembly design featuring a top plate and bus bar frames thermally fused or bolted together, with bus bars and frames made of different materials, allowing for simplified assembly processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If bus bar frames and top plate are made of different materials and thermally fused, then assembly complexity is reduced and productivity is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improveassembly productivityVSAvoidthermal fusion precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The bus bar frame and top plate are merged into a single integrated component through thermal fusion, eliminating the need for separate assembly steps. This combining of previously separate components into one unified structure directly reduces assembly complexity and improves productivity while maintaining electrical conductivity and structural integrity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The traditional mechanical fastening system (bolts, screws, or clips) is replaced with thermal fusion technology. This substitution uses heat and pressure to create a permanent bond between the bus bar frame and top plate, eliminating the need for separate fastening components and assembly operations, thereby simplifying the manufacturing process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If bus bar frames are thermally fused to the top plate, then structural integrity is improved, but manufacturing process complexity increases

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The bus bar frame and top plate are merged into a single integrated component through thermal fusion, eliminating the need for separate assembly steps. This combining of previously separate components into one unified structure directly reduces assembly complexity and improves productivity while maintaining electrical conductivity and structural integrity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The traditional mechanical fastening system (bolts, screws, or clips) is replaced with thermal fusion technology. This substitution uses heat and pressure to create a permanent bond between the bus bar frame and top plate, eliminating the need for separate fastening components and assembly operations, thereby simplifying the manufacturing process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If bus bar frames include insulating material, then short circuit prevention is improved, but electrical conductivity may be reduced

Engineering Contradiction:

Improveshort circuit preventionVSAvoidelectrical conductivity

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The bus bar frame uses composite materials with different properties in different regions: conductive materials (such as aluminum or copper) in areas requiring electrical connection, and insulating materials (such as plastic or ceramic) in areas requiring electrical isolation. This localized differentiation of material properties ensures both reliable electrical conductivity where needed and effective short circuit prevention where required.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The bus bar frame is constructed using composite materials that combine conductive and insulating properties within a single structure. This allows the frame to simultaneously provide electrical pathways for current flow and electrical isolation to prevent short circuits, resolving the contradiction between conductivity and insulation requirements.

Inventive Principle:

Principle #40Composite materials

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 enhances productivity by omitting the need for separate bus bar assembly steps, improving mechanical robustness and reliability through thermal fusion and bolting, while preventing short circuits.

Implementation Method 1

The bus bar frame may be thermally fused to the top plate

Methodology Applied

Scientific EffectThermal fusion: Welding

Data Source

PatentUS20260088431A1Battery Cell Assembly

Publication Date: 2026.03.26 LG ENERGY SOLUTION LTD

AI summary

Provided is a battery cell assembly according to example embodiments. The battery cell assembly includes a cell stack including a plurality of pouch type battery cells, and a top plate assembly on the cell stack, in which the top plate assembly includes a top plate, a bus bar frame coupled to the top plate, and a plurality of bus bars on the bus bar frame, and each of the bus bar frames includes a material different from a material of the top plate.