Battery Module Cap Plate Groove Pattern Vibration Attenuation
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Solution Overview
Problem
Conventional battery modules face challenges in maintaining process stability during manufacturing, particularly with the connection of terminals and current collectors, which can lead to vibration-induced damage and reduced welding strength, affecting the overall reliability and performance of the battery module.
Innovation Solution
The battery module incorporates a cap assembly structure with a groove pattern around the safety vent to attenuate vibrations and a fixing member with a plastic mold structure that includes insulating gaskets and connectors with bending parts to securely attach the terminal plates to the cap plate, enhancing the connection strength and reducing the risk of damage during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ultrasonic welding is used to connect terminals to the cap plate, then connection strength is improved, but vibration-induced damage to the safety vent occurs
Solution Approach 1:
A groove pattern is introduced as an intermediary structural feature between the welding area and the safety vent. This groove pattern acts as a vibration buffer that absorbs and dissipates ultrasonic welding vibrations, preventing them from reaching and damaging the safety vent while maintaining effective electrical connection between terminals and the cap plate.
Solution Approach 2:
The cap plate structure is segmented by introducing grooves that divide the plate into distinct zones. These grooves create vibration isolation zones that separate the high-vibration welding area from the safety vent area, allowing the safety vent to remain intact while still enabling strong terminal connections through controlled vibration pathways.
2Volume of moving object
If the terminal plate is positioned close to the cap plate for compact design, then device compactness is improved, but connection stability deteriorates
Solution Approach 1:
The groove pattern is designed in advance to counteract potential vibration-induced instability. By pre-positioning these vibration-absorbing grooves around the safety vent area, the structure proactively prevents vibration transmission that could compromise connection stability, even when the terminal plate is positioned close to the cap plate for compact design.
3Reliability
If the safety vent area is reinforced to prevent damage, then reliability is improved, but welding effectiveness deteriorates due to vibration transmission
Solution Approach 1:
The groove pattern creates local structural variations in the cap plate, concentrating vibration absorption properties in specific zones around the safety vent. This localized approach protects the safety vent area from vibration damage while maintaining welding effectiveness in the terminal connection areas, achieving both reliability and manufacturing effectiveness without requiring overall reinforcement of the entire cap plate.
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 improves the process stability and reduces the risk of damage to the safety vent during ultrasonic welding, ensuring a stronger connection between the terminals and the cap plate, thereby enhancing the reliability and performance of the battery module.
Implementation Method 1
a groove pattern in an area of the cap plate adjacent to the safety vent
Data Source
AI summary
A battery module includes an electrode assembly in a case, at least one current collector in the case, the current collector being electrically connected to the electrode assembly, a cap plate covering the case, the cap plate including a safety vent and at least one terminal inserter penetrating the cap plate, at least one terminal part including a terminal plate outside the case and a connector connecting the at least one current collector to the terminal plate through the at least one terminal inserter, at least one fixing member fixing the terminal part into the cap plate, and a groove pattern in an area of the cap plate adjacent to the safety vent.