Battery Module Outermost Electrode Terminal Thickness Design
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Solution Overview
Problem
Existing battery modules are prone to electrode terminal breakage due to external impact or vibration, particularly in vehicles, where the terminals' low mechanical rigidity and uniform thickness lead to reliability and safety issues, and increased welding energy and defect rates.
Innovation Solution
A battery module design where the outermost electrode terminals have a larger thickness than the rest, enhancing their resistance to external forces and allowing for easier welding, while maintaining the same width, thereby improving connection reliability and safety, and reinforcing structural weaknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the electrode terminals are made thinner to reduce weight and size, then the weight and size of the battery module are reduced, but the electrode terminals become more susceptible to breakage from external impact and vibration
Solution Approach 1:
The patent applies different thicknesses to different electrode terminals based on their functional requirements. Outermost electrode terminals have increased thickness (0.7-1.5mm) to withstand external impact and vibration, while internal electrode terminals maintain thinner dimensions (0.5mm or less) to minimize weight and size. This local differentiation of quality resolves the contradiction between weight reduction and breakage resistance.
2Strength
If the thickness of electrode terminals is increased to prevent breakage, then the resistance to external impact and vibration is improved, but the welding energy required and defect rate increase
Solution Approach 1:
The patent implements local quality enhancement by increasing thickness only for outermost electrode terminals that require high strength, while keeping internal terminals thin for ease of manufacturing. This selective approach ensures that welding operations on the majority of terminals remain simple and low-cost, while only the critical outermost terminals require higher welding energy, thus resolving the contradiction between strength and manufacturability.
3Ease of manufacture
If uniform thickness is used for all electrode terminals, then the manufacturing process is simplified, but the outermost terminals are vulnerable to breakage from vibration and impact
Solution Approach 1:
The patent applies local quality differentiation where outermost electrode terminals have increased thickness (0.7-1.5mm) to provide structural integrity against vibration and impact, while internal terminals maintain uniform thin dimensions for simplified manufacturing. This resolves the contradiction by localizing the complexity enhancement only where structurally necessary.
Solution Approach 2:
The patent introduces asymmetry in electrode terminal dimensions, breaking the uniformity of the manufacturing process. Outermost terminals are deliberately made thicker than internal terminals, creating an asymmetric structure that provides enhanced protection at critical locations while maintaining manufacturing efficiency for the majority of terminals.
Data Source
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AI summary
Disclosed herein is a battery module including a plurality of plate-shaped battery cells which are sequentially stacked, wherein the battery module is configured to have a structure in which two or more hexahedral cell units are connected to each other in series in a state in which the hexahedral cell units are stacked, each of the cell units is configured to have a structure in which two or more battery cells are connected to each other in series in a state in which the battery cells are in tight contact with each other, and electrode terminals (outermost electrode terminals) of outmost battery cells of the cell units are connected to external input and output terminals of the battery module, the outermost electrode terminals having a larger vertical sectional area than electrode terminals of the other battery cells such that the outermost electrode terminals are prevented from being broken by external force.