Battery Module with Bent Electrode Leads and Through-Hole Coupling

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Pouch-shaped secondary battery modules face challenges with increased size due to protruding electrode terminals, complex welding processes, and insufficient sealability at the seamed regions, leading to potential separation under harsh conditions.

Innovation Solution

The battery module design involves bending electrode leads and placing them on the upper-end sealing part, forming through-holes for mechanical and electrical coupling, using conductive coupling members like fasteners, and interposing insulative members to prevent contact and enhance sealability, allowing for reduced volume and improved electrical and mechanical connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If electrode terminals are connected via wires, plates, or bus bars using welding, then electrical connection is achieved, but the manufacturing process becomes complicated and difficult

Engineering Contradiction:

Improveelectrical connectionVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the welding process (thermal/mechanical system) with a mechanical insertion system. Conductive coupling members are simply inserted through aligned through-holes in the electrode leads and sealing part, eliminating the need for complex welding operations while maintaining electrical connection reliability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces conductive coupling members as intermediary components that facilitate electrical connection. These coupling members serve as mediators between electrode leads and sealing parts, providing a simpler alternative to direct welding while ensuring reliable electrical connectivity

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If electrode terminals protrude to the outside, then electrical connection is enabled, but the size of the pouch-shaped battery increases

Engineering Contradiction:

Improveelectrical connectionVSAvoidbattery size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent utilizes the thickness direction (z-axis) by stacking unit cells vertically and routing electrode leads through the sealing part in this dimension. This allows electrical connection without requiring lateral protrusion of terminals, thereby reducing the overall battery volume while maintaining connectivity

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 design reduces the battery module's size, enhances sealability, and simplifies electrical and mechanical coupling, ensuring stable connections and increased structural stability without the need for conventional mounting members.

Implementation Method 1

conductive coupling members are inserted through the through-holes of the unit cells, respectively, whereby the electrical connection and the mechanical coupling between components constituting the battery module are accomplished

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

through-holes for mechanical coupling and electrical connection are formed in the electrode leads and the sealing part such that the through-holes of the electrode leads communicate with the corresponding through-holes of the sealing part, respectively, and conductive coupling members are inserted through the through-holes of the unit cells

Methodology Applied

Scientific EffectMechanical fastening: Mechanical Fastener

Data Source

PatentUS8808908B2Battery module of novel structure

Publication Date: 2014.08.19 LG ENERGY SOLUTION LTD

AI summary

A battery module has a plurality of batteries, each having an electrode assembly mounted in a battery case including a metal layer and a resin layer, as unit cells, are stacked one on another in the thickness direction, wherein the battery module is constructed such that electrode leads of each unit cell are bent and placed on an upper-end sealing part of each unit cell, through-holes for mechanical coupling and electrical connection are formed in the electrode leads and the sealing part such that the through-holes of the electrode leads communicate with the corresponding through-holes of the sealing part, respectively, and conductive coupling members are inserted through the through-holes of the unit cells. The battery module accomplished a maximum reduction in volume, increasing sealability of the sealing part, and easily accomplishing the electrical connection and the mechanical coupling between components.