Battery Pack Sense Lead and Tab Terminal Welded Retention
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Solution Overview
Problem
Existing battery pack terminal retention systems in traction battery packs face complexity in securely connecting and monitoring tab terminals to sense leads, which affects the structural integrity and monitoring capabilities of the battery pack.
Innovation Solution
A battery pack terminal retention system that secures tab terminals directly to a sense lead using welds and a cross-member, with heat stakes for additional support, allowing for efficient electrical connection and monitoring, and utilizing a jumper to couple the sense lead to a monitoring module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional terminal retention systems are used to securely connect tab terminals to sense leads, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The patent combines the terminal retention system components (cross-member, sense lead, tab terminals, welds, and heat stakes) into an integrated assembly where multiple functions are performed by a unified structure. The cross-member serves as both a structural support and a mounting platform for the sense leads, while the welds simultaneously provide both mechanical retention and electrical connection, thereby reducing overall system complexity while maintaining connection reliability.
Solution Approach 2:
The cross-member is designed to serve multiple functions: it provides structural support for the battery pack, serves as a mounting platform for sense leads, and facilitates both mechanical retention and electrical connection of tab terminals. This multi-functional design eliminates the need for separate components for each function, thereby reducing device complexity while ensuring reliable connections.
2Strength
If multiple components are used to secure tab terminals to sense leads, then connection strength is improved, but manufacturing complexity increases
Solution Approach 1:
The tab terminals are pre-formed with folded configurations before assembly, and the cross-member is pre-equipped with apertures and positioning features. This preliminary preparation allows for simplified assembly operations during manufacturing, as components are designed to fit together in predetermined configurations, reducing the complexity of the manufacturing process while ensuring strong connections through pre-engineered joint geometries.
Solution Approach 2:
The patent replaces complex mechanical retention mechanisms with a combination of welding and thermalstaking processes. Instead of using multiple mechanical fasteners or complex retention structures, the connection is achieved through metallurgical bonding (welding) and localized melting (thermalstaking), which simplifies the manufacturing process while providing strong, reliable connections between tab terminals and sense leads.
3Reliability
If tab terminals are folded over the sense lead, then electrical connection is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent specifies particular geometric parameters for the folded tab terminals, including fold angles, overlap dimensions, and positioning relative to the sense lead. By defining these parameters within acceptable tolerances, the design accommodates normal manufacturing variations while ensuring reliable electrical connection. The folded configuration is designed to provide adequate contact area and mechanical retention even with moderate manufacturing precision.
Solution Approach 2:
The connection system utilizes composite construction combining the tab terminal material (typically aluminum or copper), the sense lead material, and the cross-member material (often composite or metal). This composite approach allows for differential thermal expansion and flexibility in the folded configuration, accommodating manufacturing tolerances while maintaining reliable electrical connection through the combined properties of the different 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 system simplifies the connection process, enhances structural integrity, and facilitates effective monitoring of battery conditions, reducing overall system complexity and improving reliability.
Implementation Method 1
a plurality of welds that secure the plurality of tab terminals directly to the sense lead
Implementation Method 2
at least one heat stake securing the sense lead to the cross-members
Data Source
AI summary
A battery pack terminal retention system includes a sense lead, and a plurality of tab terminals secured directly to each other and to the sense lead. A battery pack terminal retention method includes securing a plurality of tab terminals to a sense lead; and monitoring a voltage using the sense lead. The tab terminals can be secured to the sense lead via welds.