Recessed Battery Module Terminal Integration
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Solution Overview
Problem
Traditional battery module configurations face challenges with high material costs, manufacturing complexity, and exposure to short circuits due to bulky and exposed connections between major bus bars and terminals, which require compatible materials for welding and compromise energy density.
Innovation Solution
The integration of major terminals within a recessed housing, allowing for electrical coupling without welding, using different materials for the base and post, and sealing the terminal within the housing to eliminate external connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional welding connections are used between major bus bars and terminals, then electrical coupling is established, but material costs increase and manufacturing complexity increases
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical press-fit connection. The major terminal is inserted into a recess in the housing, and the bus bar is pressed onto the terminal, establishing electrical coupling through direct mechanical contact rather than welding. This eliminates the need for welding equipment, material compatibility considerations, and complex welding procedures.
2Reliability
If traditional exposed connections are used between major bus bars and terminals, then electrical coupling is established, but the risk of short circuits increases
Solution Approach 1:
The patent nests the major terminal within a recess of the housing, and the bus bar connection within the terminal structure. This nested arrangement conceals the electrical connection components within the housing rather than exposing them externally, thereby eliminating the risk of external short circuits while maintaining electrical coupling functionality.
3Reliability
If traditional bulky connections are used between major bus bars and terminals, then electrical coupling is established, but energy density decreases
Solution Approach 1:
The patent merges the major terminal with the housing structure by integrating the terminal recess directly into the housing body. This consolidation eliminates separate connection components and reduces the overall volume occupied by electrical connection structures, thereby increasing the space available for energy-storing battery cells and improving energy density.
Data Source
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AI summary
The present disclosure includes a group of electrically interconnected battery cells disposed within a housing. The disclosure also includes a major terminal of a battery module configured to be coupled to a load for powering the load. One or more portions of the major terminal are disposed within a recess in a surface of the housing. The present disclosure also includes a bus bar that provides an electrical pathway between the group of electrically interconnected battery cells and the major terminal. The bus bar is disposed within the housing.