Battery Module Connection Plate Layout for Higher Cell Density
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Solution Overview
Problem
Conventional battery packs face limitations in energy density due to the need for separate space for welding metal plates, which reduces the number of cylindrical battery cells that can be accommodated and generates heat, affecting the pack's stability and longevity.
Innovation Solution
The battery pack design incorporates connection plates with bent portions that extend to the outer walls of the module housing, eliminating the need for internal welding space, and includes air holes for heat dissipation and a tray with electromagnetic shielding to prevent malfunction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal plates are used for electrical connection inside module housing, then electrical connectivity is achieved, but welding space is required which reduces energy density
Solution Approach 1:
The connection plate extends from the internal contact portion through the module housing wall to the external connection portion, utilizing the third dimension (depth/length through the wall) to establish electrical connection between modules without requiring internal welding space. This dimensional transition allows modules to be connected in series while maximizing the space available for battery cells.
2Power
If metal plates are welded for high-rate power transmission, then power transmission capability is improved, but heat generation increases affecting stability
Solution Approach 1:
The welding process is extracted from the internal module housing environment and relocated to the external connection portion between modules. This separation removes the heat-generating welding operation from the thermal-sensitive internal environment, allowing high-rate power transmission through welded connection plates while preventing heat damage to battery cells and internal components.
3Quantity of substance
If more battery cells are accommodated in limited space, then capacity is increased, but space for connection components is reduced
Solution Approach 1:
The connection plate utilizes the vertical dimension by extending through the module housing wall, allowing electrical connection to be established in the depth direction rather than requiring horizontal welding space. This enables closer arrangement of battery cells in the limited horizontal space while maintaining necessary connection functionality.
Data Source
AI summary
A battery pack includes a plurality of battery modules disposed in a front and rear direction. Each of the battery modules includes a plurality of battery cells; a module housing; and a connection plate including a contact portion at an upper or lower portion of the plurality of battery cells and having a plurality of connection terminals in a portion thereof and respectively electrically contacted and connected to the electrode terminals at the plurality of battery cells, and a connection portion bent at least once from one end of the contact portion to extend in at least one direction among an upper direction, a lower direction, a front direction and a rear direction so that the bent and extending region of the connection portion is on a left or right outer wall of the module housing to contact a part of a connection plate of another battery module.