Sacrificial Bus Bar Interconnect for Battery Pack Assembly
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Solution Overview
Problem
Conventional wire bonding in battery pack assembly is time-consuming and costly, introducing reliability issues and limiting the efficiency of electric vehicle battery pack manufacturing.
Innovation Solution
A bus bar interconnect system using sacrificial and primary interconnects, where the sacrificial interconnect makes initial contact with the battery terminal to prevent arcing and damage, followed by attachment of the primary interconnect using techniques like laser welding, allowing for efficient assembly and reducing manufacturing time and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire bonding is used to interconnect batteries, then electrical connection is achieved, but assembly time increases and manufacturing cost increases
Solution Approach 1:
The interconnect system is segmented into two distinct components: a sacrificial interconnect and a primary interconnect. The sacrificial interconnect makes initial contact during assembly to enable welding, then is removed, leaving only the primary interconnect for the final electrical connection. This segmentation allows for simplified assembly positioning while maintaining reliable electrical connection through the primary interconnect.
Solution Approach 2:
The sacrificial interconnect serves as an intermediary element during the assembly process. It facilitates the welding operation by providing initial contact and positioning, then is discarded after serving its purpose. This intermediary approach enables efficient assembly without requiring the primary interconnect to perform both positioning and electrical connection functions simultaneously.
2Reliability
If wire bonding is used to interconnect batteries, then electrical connection is achieved, but manufacturing cost increases
Solution Approach 1:
The interconnect system is segmented into two distinct components: a sacrificial interconnect and a primary interconnect. The sacrificial interconnect makes initial contact during assembly to enable welding, then is removed, leaving only the primary interconnect for the final electrical connection. This segmentation allows for simplified assembly positioning while maintaining reliable electrical connection through the primary interconnect.
Solution Approach 2:
The sacrificial interconnect is designed as a disposable, low-cost component that serves its purpose during assembly and is then removed. By using a cheap, expendable element for the temporary assembly function, the overall manufacturing cost is reduced compared to using expensive wire bonding materials and processes for both positioning and connection.
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
The solution enables quick and reliable assembly of battery packs, reducing manufacturing time and cost while minimizing the risk of arcing and terminal damage, thereby enhancing the reliability and efficiency of electric vehicle battery packs.
Implementation Method 1
the sacrificial interconnect makes initial contact with the battery terminal to prevent arcing and damage
Implementation Method 2
attaching the primary interconnect to the battery terminal may utilize a technique selected from the group consisting of laser welding
Data Source
AI summary
A method is provided for interconnecting the batteries in a battery pack in a manner that is designed to minimize damage and contamination of the contact surfaces of the interconnect and the battery terminal, thereby minimizing connection resistance and increasing interconnect reliability.