Battery Module Stepped Bus Plate Layout for Tab Stability
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Solution Overview
Problem
Existing battery modules face challenges in maintaining mechanical and electrical stability, particularly in high-power applications where repeated charging and discharging lead to potential deformation or fracture of connection tabs.
Innovation Solution
A battery module design featuring a plurality of battery cells with negative and positive electrodes, first and second conductive plates, and insulative plates, where connection tabs are strategically positioned to prevent deformation and fracture, and a cooling member is integrated for improved spatial efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connection tabs are used to electrically connect battery cells to conductive plates, then electrical connectivity is achieved, but the connection tabs may deform or fracture under repeated charging and discharging cycles
Solution Approach 1:
The conductive plate is divided into multiple stepped portions at different heights, with each portion independently supporting connection tabs from different battery cells. This segmentation allows each connection tab to be positioned at an optimal height, reducing mechanical stress and preventing deformation during repeated charging cycles.
Solution Approach 2:
The invention introduces a vertical dimension by creating stepped portions at different heights on the conductive plate. Instead of all connection tabs being at the same level, they are arranged at multiple height levels, which distributes mechanical stress and prevents fracture while maintaining electrical connectivity.
2Power
If multiple battery cells are electrically connected to increase power and capacity, then high-power applications are enabled, but maintaining stable mechanical and electrical connection becomes more difficult
Solution Approach 1:
The conductive plate is segmented into multiple stepped portions, each capable of supporting connection tabs from different battery cells. This allows systematic organization of multiple battery cells while maintaining individual connection stability, enabling high-power applications without compromising connection reliability.
Solution Approach 2:
The stepped portions of the conductive plate act as intermediaries between battery cells and the main conductive structure. Each stepped portion provides a dedicated mounting point that ensures stable mechanical and electrical connection, facilitating the reliable integration of multiple battery cells for high-power applications.
3Reliability
If connection tabs are positioned to optimize electrical connection, then electrical conductivity is improved, but mechanical stability and resistance to deformation deteriorate
Solution Approach 1:
By introducing vertical height variations through stepped portions, the invention allows connection tabs to be positioned at optimal heights for both electrical conductivity and mechanical stability. The vertical dimension provides additional freedom in positioning, enabling simultaneous optimization of both electrical and mechanical properties.
Solution Approach 2:
Different stepped portions are created at different heights, with each portion optimized for its specific function. Connection tabs requiring better mechanical stability can be positioned at lower stepped portions, while those requiring optimal electrical contact can be positioned at higher portions, allowing local optimization of both properties.
Data Source
AI summary
An embodiment of the present disclosure provides a battery module including: battery cells including negative and positive electrodes on the same side; a first conductive plate provided at end portions of the battery cells and adjacent to the negative and positive electrodes, the first conductive plate including first through-holes through which the negative and positive electrodes are respectively exposed and first stepped portions which are adjacent to the first through-holes and recessed toward the battery cells; an insulative plate arranged on the first conductive plate and including second through-holes which at least partially overlap the first through-holes; a second conductive plate on the insulative plate, the second conductive plate including third through-holes which at least partially overlap the second through-holes and second stepped portions which are adjacent to the third through-holes and recessed toward the insulative plate; first connection tabs electrically connecting the positive electrodes or the negative electrodes to the first stepped portions; and second connection tabs electrically connecting the others of the positive electrodes and the negative electrodes to the second stepped portions.