Press-Fit Battery Cell Coupling Plates for Weld-Free Pack Assembly
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Solution Overview
Problem
Conventional battery pack structures face challenges in reducing manufacturing costs due to the complexity of bus bar coupling and the need for frequent welding or bolt fastening, especially in large-scale applications like electric vehicles, which increases production time and complexity.
Innovation Solution
A battery-cell coupling structure using two types of electrode coupling plates, namely, first and second electrode coupling plates, which are press-fitted between battery cells to achieve series, parallel, or series-parallel connections without welding or bolt fastening, simplifying the manufacturing process and reducing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bus bars are used to electrically couple battery modules with various shapes according to predetermined voltage, then electrical coupling is achieved, but manufacturing cost increases and device complexity increases
Solution Approach 1:
The patent applies universality by designing a single standardized bus bar shape that can serve multiple coupling positions and configurations. Instead of preparing various shaped bus bars for different voltage requirements, the invention uses one universal bus bar design that can be adapted to different coupling needs through its standardized interface, thereby reducing manufacturing complexity while maintaining reliable electrical coupling.
Solution Approach 2:
The patent applies segmentation by dividing the battery pack into standardized modules that can be coupled using identical bus bars. The battery modules are designed with standardized terminals and coupling interfaces, allowing the same bus bar shape to be used across multiple modules and configurations, reducing the need for custom-shaped bus bars.
2Reliability
If welding or bolt fastening is used to couple bus bars to battery terminals, then electrical coupling is achieved, but manufacturing time increases and productivity decreases
Solution Approach 1:
The patent replaces the mechanical welding or bolt fastening system with a simpler mechanical insertion system. The bus bars are designed to be directly inserted into and coupled with battery terminals through friction-fit or snap-fit mechanisms, eliminating the need for welding equipment, heat treatment processes, or bolt tightening operations, thereby significantly increasing assembly speed and productivity.
Solution Approach 2:
The patent applies preliminary action by pre-forming the bus bars and battery terminals with complementary coupling geometries during manufacturing. The coupling interfaces are prepared in advance with precise dimensions and features that enable direct mechanical coupling, eliminating the need for on-site welding or fastening operations and streamlining the assembly process.
3Reliability
If multiple battery modules are stacked and coupled via brackets and bus bars, then voltage and capacity requirements are met, but manufacturing cost increases
Solution Approach 1:
The patent applies universality by designing standardized battery modules with uniform terminals and coupling interfaces. This allows the same modules to be stacked and coupled in various configurations to achieve different voltage and capacity requirements, eliminating the need for custom-designed modules for each application and reducing manufacturing costs through economies of scale.
Solution Approach 2:
The patent merges the functions of electrical coupling and mechanical support into a single integrated bus bar design. The bus bars serve both as electrical conductors and as structural elements that provide mechanical support and alignment between stacked modules, reducing the need for separate brackets and fasteners, thereby lowering manufacturing costs.
Data Source
AI summary
A battery-cell coupling structure includes battery cells arranged in a first direction, a first electrode coupling plate including an insulating substrate and a first coupling terminal provided at a first end of the insulating substrate in a second direction orthogonal to the first direction, and a second electrode coupling plate including the insulating substrate, the first coupling terminal, and a second coupling terminal provided at a second end of the insulating substrate in the second direction. The battery-cell coupling structure is configured to electrically couple the battery cells to each other. Each of the battery cells includes a first electrode provided at a first end in the second direction and a second electrode provided at a second end in the second direction. The battery cells are coupled in series, parallel, or series-parallel with one or both of the first electrode coupling plate and the second electrode coupling plate.