Battery Module Electrode Tab Protrusion Design
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Solution Overview
Problem
The existing methods for connecting electrode tabs to electrode terminals in battery modules often result in leakage currents, leading to insufficient coupling and inefficiencies in the welding process, which increases costs and time.
Innovation Solution
A battery module design that includes a first and second battery cell with electrode tabs featuring extension portions, coupling regions, and a protrusion portion to minimize leakage currents during welding, improving the coupling force and efficiency of the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding current is applied to electrode tab and electrode terminal, then electrical connection is achieved, but leakage current occurs at portions other than electrode terminal resulting in insufficient coupling
Solution Approach 1:
The protrusion portion acts as an intermediary element between the electrode tab and the battery cell body. It provides a dedicated path for welding current to flow from the electrode tab to the electrode terminal, preventing current leakage through the battery cell body. This mediator structure ensures that the welding current is confined to the intended connection path, improving coupling force while reducing energy loss through leakage.
Solution Approach 2:
The invention introduces a vertical dimension by adding the protrusion portion that extends upward from the battery cell body. This three-dimensional structure allows the electrode tab to make contact with the electrode terminal through the protrusion, creating a dedicated current path that separates the welding current flow from the battery cell body, thereby preventing leakage current while ensuring reliable electrical connection.
2Productivity
If conventional welding method is used, then electrode tab is connected to electrode terminal, but welding efficiency is reduced due to leakage current
Solution Approach 1:
The protrusion portion serves as a mediator that directs welding current efficiently along the intended path from electrode tab to electrode terminal. By providing this intermediate structure, the welding process becomes more efficient as current leakage through the battery cell body is prevented, reducing energy waste and improving overall welding productivity.
3Reliability
If leakage current occurs during welding, then insufficient coupling is formed, but additional welding time and cost are required
Solution Approach 1:
The protrusion portion is pre-formed on the battery cell body before the welding process. This preliminary structure ensures that when the electrode tab is positioned and welded, the current path is already established and optimized. The pre-existing protrusion prevents leakage current from the outset, ensuring sufficient coupling force is achieved in a single welding operation, thereby reducing welding time and cost.
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 design enhances the coupling force between the electrode tab and terminal, reduces leakage currents, and improves welding efficiency, thereby reducing costs and time required for welding.
Implementation Method 1
an electrode tab electrically connecting the first terminal and the second terminal to each other
Implementation Method 2
the electrode tab may be welded to the electrode terminals
Data Source
AI summary
A battery module includes: a first battery cell including a first terminal at a top surface thereof; a second battery cell arranged adjacent to the first battery cell and including a second terminal arranged at a top surface thereof in substantially parallel to the first terminal; and an electrode tab electrically connecting the first terminal and the second terminal to each other, wherein the electrode tab includes: a first extension portion coupled to the first terminal and extending along an adjacent side portion of the first battery cell and the second battery cell; a second extension portion coupled to the second terminal and extending along the adjacent side portion in substantially parallel to the first extension portion; and a connection portion connected to the first extension portion and the second extension portion and including a protrusion portion protruding upward from the first battery cell and the second battery cell.