Battery Module Holder Ribs for Stable Tab-Busbar Fixation
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Solution Overview
Problem
Rechargeable battery modules face challenges in maintaining adherence and stable fixation of tabs and busbars when the space between adjacent core packs is narrow, making it difficult to form guide bosses and use screws or bolts effectively.
Innovation Solution
The rechargeable battery module design includes a holder with internal and external rib members that are independently spaced and integrally formed, allowing for the secure fixation of tabs and busbars, even in tight spaces, by creating gaps that accommodate the lateral portions of the tabs and busbars, ensuring robust adherence and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If core packs are disposed near with each other in horizontal direction to provide large capacity, then battery capacity is improved, but the space between core packs becomes narrow making it difficult to form guide boss and guide rib and use screws or bolts
Solution Approach 1:
The holder is segmented into multiple functional regions: a receiving space for battery cells, a first space for the tab, and a second space for the busbar. This segmentation allows each component to be positioned and fixed independently, enabling reliable connections even in narrow spaces between core packs where traditional guide bosses and ribs cannot be formed.
Solution Approach 2:
The invention transitions from a two-dimensional planar arrangement (guide boss and guide rib on the holder surface) to a three-dimensional spatial arrangement using vertically extending first and second spaces. This dimensional change allows the tab and busbar to be fixed in the vertical direction within the holder, bypassing the limitation of narrow horizontal spaces between core packs.
2Volume of stationary object
If space between adjacent core packs is narrow, then battery module density is improved, but adherence between tab and busbar cannot be maintained and stable fixation cannot be achieved
Solution Approach 1:
The tab is nested within the first space of the holder, and the busbar is nested within the second space. This nested arrangement ensures that both components are securely contained and positioned within the holder structure, maintaining reliable adherence and fixation even when the horizontal space between core packs is minimized for high density.
Solution Approach 2:
The holder acts as an intermediary structure between the battery cells, tab, and busbar. It provides dedicated spaces that mediate the connection between these components, ensuring stable fixation and reliable electrical connections independent of the narrow spacing between adjacent core packs.
3Stability of the object's composition
If traditional fixation methods (guide boss, guide rib, screws, or bolts) are used, then tab and busbar can be fixed, but they cannot be used when space between core packs is narrow
Solution Approach 1:
The holder performs multiple functions: it receives and positions battery cells, provides a first space for tab fixation, and provides a second space for busbar fixation. This multi-functional design eliminates the need for separate guide bosses, guide ribs, and fasteners, making the structure adaptable to narrow space configurations while maintaining fixation stability.
Data Source
AI summary
A rechargeable battery module includes a holder configured to accommodate battery cells spaced in from each other in a first direction and a second direction crossing the first direction; tabs configured to electrically connect the battery cells to each other, at least one of the tabs having an inner planar portion and an inner lateral portion bent from the inner planar portion and fixed to a side of the holder; and busbars configured to connect the tabs to a battery management system. At least one of the busbars has an outer lateral portion connected to the inner lateral portion of the tab and an outer planar portion bent from the outer lateral portion and spaced from the inner planar portion. The holder includes a rib configured to fix at least one of the inner lateral portion of the tab and the outer lateral portion of the busbar.