Battery Module Connection Board With Welded Insertion Protrusions
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Solution Overview
Problem
Conventional battery modules face increased complexity and higher manufacturing costs due to the use of balancing wires, which can cause short-circuits and complicate internal configurations, thereby reducing durability and increasing material costs.
Innovation Solution
A battery module design that eliminates the need for balancing wires by using insertion protrusions from electrode tabs welded to a connection board and a connector system with a first and second connection portion to connect the protection circuit board, simplifying the manufacturing process and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If balancing wires are used to connect electrode tabs to the protection circuit board, then electrical connections can be established, but the internal configuration becomes complex and manufacturing costs increase
Solution Approach 1:
The patent extracts and eliminates the balancing wire from the battery module structure. Instead of using separate wires to connect electrode tabs to the protection circuit board, the invention integrates the connection function directly into the electrode tab structure through insertion protrusions that fit into the connection board, thereby simplifying the internal configuration while maintaining reliable electrical connections.
Solution Approach 2:
The invention merges the functions of the electrode tab and the connection element into a single integrated structure. The insertion protrusion is formed as an integral part of the electrode tab, combining the electrical conduction function with the mechanical connection function, thus eliminating the need for separate balancing wires and reducing structural complexity.
2Reliability
If balancing wires are used for connecting components, then electrical connections are established, but manufacturing costs increase due to additional materials and processes
Solution Approach 1:
The patent removes the balancing wire component entirely from the manufacturing process. By forming the insertion protrusion directly on the electrode tab through processes like extrusion or injection molding, the invention eliminates the need to purchase, handle, and install separate wire components, thereby reducing material costs and simplifying the manufacturing process.
Solution Approach 2:
The electrode tab structure serves its own connection function through the integrated insertion protrusion. Rather than requiring external wires to establish electrical connections, the electrode tab itself provides the connecting element, reducing the number of components and manufacturing steps required.
3Reliability
If balancing wires are used to connect electrode tabs, then electrical connections can be made, but the risk of short-circuits increases
Solution Approach 1:
The patent removes the balancing wire that poses a short-circuit risk. By replacing the wire with an integrated insertion protrusion formed as part of the electrode tab structure, the invention eliminates the harmful factor of loose wire connections that could cause short-circuits, while maintaining stable electrical connections through the precise fit of the protrusion into the connection board.
4Reliability
If conventional wire-based connections are used, then electrical connections are established, but the manufacturing process becomes more complex
Solution Approach 1:
The invention combines the electrode tab and connection element into a single integrated component. The insertion protrusion is formed as part of the electrode tab structure, merging the electrical conduction function with the mechanical connection function, thereby simplifying the manufacturing process by reducing the number of assembly steps and components.
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 simplifies the manufacturing process, reduces material costs, and improves durability by eliminating the risk of short-circuits and internal complexity, while maintaining stable electrical connections between rechargeable batteries.
Implementation Method 1
the insertion protrusions are welded to the connection board
Data Source
AI summary
A battery module is disclosed. In one aspect, the battery module includes a plurality of rechargeable batteries and a plurality of electrode tabs connecting the rechargeable batteries. The battery module also includes a connection board electrically connecting the electrode tabs and a connector connecting the connection board and a protection circuit board. According to some embodiments, a process for manufacturing the battery module is simplified and material costs are reduced.