Battery Module Lead Pre-Bending to Prevent Electrode Tab Strain
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Solution Overview
Problem
Existing methods for assembling battery modules and packs introduce mechanical strain on electrode tabs during assembly, leading to reduced lifetime due to lateral deflection and interference of conductive leads, particularly in pouch-type batteries.
Innovation Solution
The conductive leads are pre-bent according to the predetermined position of the battery cell in the housing to minimize mechanical strain, with a bent portion extending at an angle from the proximal portion towards the lead terminal, ensuring the lead is aligned without additional bending during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conductive leads are fitted through lead holes without alignment to battery cell position, then assembly ease is improved, but mechanical strain on electrode tabs increases leading to reduced lifetime
Solution Approach 1:
The conductive lead is pre-bent to a predetermined angle corresponding to the specific position of the battery cell in the housing before assembly. This preliminary action ensures that when the battery cell is inserted, the lead extends directly from the bent portion toward the lead terminal without requiring additional bending or adjustment during assembly, thus avoiding mechanical strain on the electrode tabs while maintaining assembly efficiency
Solution Approach 2:
Different battery cells at different positions in the housing have conductive leads bent at different predetermined angles. Each lead's bending angle is locally optimized for its specific position, ensuring proper alignment with the lead terminal while minimizing mechanical strain on the electrode tab at that particular location
2Adaptability or versatility
If conductive leads are made pliable to fit through lead holes, then ease of installation is improved, but lateral deflection of electrode tab increases causing mechanical failure
Solution Approach 1:
The conductive lead is pre-bent to the correct angle before insertion, so that during assembly it does not need to be forced or bent laterally. This eliminates the lateral deflection that would otherwise occur when inserting a straight lead into a misaligned hole, thereby preventing damage to the electrode tab while still allowing the lead to be flexible enough to accommodate the bending process
Solution Approach 2:
By pre-bending the lead to counteract the expected misalignment between the battery cell position and lead hole position, the invention creates a preliminary anti-action that offsets the harmful lateral forces that would otherwise be applied to the electrode tab during assembly
Data Source
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AI summary
A method of assembling a battery module or battery pack comprising a plurality of battery cells and a housing for holding the plurality of battery cells, the method comprising providing a battery cell comprising an electrode assembly, a case accommodating the electrode assembly, and a conductive lead connected to the electrode assembly and extending outside of the case, bending the conductive lead in accordance with a predetermined cell position of the battery cell in the housing, such that a distal portion of the conductive lead extends from a bent portion of the conductive lead at an angle with respect to a proximal portion of the conductive lead towards a lead terminal of the housing for the predetermined cell position, the proximal portion being in physical contact with the electrode assembly, and inserting the battery cell into the housing at the predetermined cell position.