Battery Pack Tab Terminal Busbar Joining for Simpler Welding
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Solution Overview
Problem
Existing battery pack terminal retention systems in electrified vehicles face challenges in securely connecting multiple tab terminals to busbars, particularly in efficiently managing terminal connections and structural integrity within the battery pack.
Innovation Solution
A battery pack terminal retention system that secures groups of tab terminals directly to different portions of a busbar using welds and heat stakes, with cross-members and composite materials to enhance structural integrity, allowing tab terminals to extend through apertures and be folded over busbar segments for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple tab terminals are connected to the busbar using traditional individual welding methods, then each terminal can be securely attached, but the manufacturing complexity and time consumption increase significantly
Solution Approach 1:
The patent combines multiple individual terminal connections into a single integrated connection structure. The busbar is designed with a unified configuration that accommodates multiple tab terminals simultaneously, allowing them to be connected through a single welding operation rather than multiple separate welds. This merging approach maintains secure attachment of each terminal while significantly simplifying the welding process and reducing manufacturing complexity.
Solution Approach 2:
The busbar is segmented into multiple connection regions, each designed to receive and secure specific tab terminals. The busbar structure includes distinct portions that can be independently welded to different terminals, allowing for modular assembly. This segmentation enables efficient connection of multiple terminals while maintaining process simplicity through standardized connection patterns.
2Reliability
If multiple tab terminals are individually secured to the busbar, then each connection can be optimized, but the manufacturing time and process complexity increase
Solution Approach 1:
The invention merges multiple terminal connection operations into a single integrated welding process. The busbar geometry is designed to accommodate multiple tab terminals in a configuration that allows simultaneous or sequential connection in one manufacturing step, thereby maintaining optimized electrical connectivity while dramatically improving manufacturing efficiency and reducing production time.
Solution Approach 2:
The busbar is pre-configured with specific geometric features, aperture positions, and connection regions before the welding process. This preliminary preparation of the busbar structure enables rapid attachment of multiple terminals without requiring complex real-time adjustments during manufacturing, thus optimizing both connection quality and production speed.
3Ease of manufacture
If tab terminals are secured using traditional methods without structural support, then the connection process is simpler, but the structural integrity of the battery pack is compromised
Solution Approach 1:
The busbar is constructed using composite material structures that combine different materials to achieve both mechanical strength and electrical conductivity. This composite construction provides enhanced structural support for the tab terminals while maintaining the simplicity of the welding connection process. The multi-material busbar structure inherently reinforces the connection points without adding complex assembly steps.
Solution Approach 2:
The busbar structure is divided into reinforced connection zones and standard connection zones. The reinforced zones provide enhanced structural support specifically at the terminal attachment points, while the rest of the busbar maintains its simplified geometry for easy manufacturing. This segmented approach strengthens the battery pack structure where needed without complicating the overall connection process.
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 effectively secures multiple tab terminals to busbars, enhancing the structural integrity and electrical connectivity of battery packs, facilitating efficient energy transfer and reducing the complexity of welding multiple terminals, thereby improving the reliability and efficiency of the battery pack.
Implementation Method 1
securing a group of more than two first tab terminals directly to each other and to a first portion of a busbar; and securing a group of more than two second tab terminals directly to each other and to a second portion of a busbar
Implementation Method 2
at least one heat stake securing the busbar to the cross-member
Data Source
AI summary
A battery pack terminal retention system includes a busbar; a group of more than two first tab terminals secured directly to each other and to a first portion of the busbar; and a group of more than two second tab terminals secured directly to each other and to a different, second portion of the busbar,