Battery Module Terminal Connecting Member Height Compensation
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Solution Overview
Problem
The uneven height differences between adjacent battery cells in battery modules can lead to non-uniform welding, compromising the quality and safety of the connections in high-capacity battery packs used in portable and large-sized apparatuses.
Innovation Solution
A battery module design featuring a terminal connecting member with first and second contact portions that include slit portions and a stepped body portion, allowing for surface contact and overcoming step differences through elasticity, ensuring secure and efficient connections between battery cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bus bar is used to connect battery cells in series or parallel, then the battery cells can be connected, but a difference in height between adjacent battery cells occurs, causing non-uniform welding
Solution Approach 1:
The terminal connecting member features contact portions with different thicknesses at different locations. The first contact portion has a first thickness and the second contact portion has a second thickness different from the first, allowing each contact portion to adapt to the specific height of adjacent battery cell terminals. This local variation in thickness enables uniform welding quality across all connections despite height differences in the battery cell array.
2Reliability
If the terminal connecting member has uniform thickness, then the structure is simple, but it cannot overcome step differences between battery cells
Solution Approach 1:
The terminal connecting member features contact portions with different thicknesses at different locations. The first contact portion has a first thickness and the second contact portion has a second thickness different from the first, allowing each contact portion to adapt to the specific height of adjacent battery cell terminals. This local variation in thickness enables uniform welding quality across all connections despite height differences in the battery cell array.
Solution Approach 2:
The invention addresses the height difference problem by introducing thickness variation in the vertical dimension of the terminal connecting member. Instead of trying to level the battery cells horizontally, the solution varies the thickness of contact portions along the vertical axis, allowing the connecting member to bridge height gaps between adjacent cells while maintaining overall structural simplicity.
3Strength
If the contact portions are made thick, then the connection strength is high, but the ability to adapt to height differences is reduced
Solution Approach 1:
The terminal connecting member features contact portions with different thicknesses at different locations. The first contact portion has a first thickness and the second contact portion has a second thickness different from the first, allowing each contact portion to adapt to the specific height of adjacent battery cell terminals. This local variation in thickness enables uniform welding quality across all connections despite height differences in the battery cell array.
Solution Approach 2:
The invention changes the thickness parameter of the contact portions to different values. The first contact portion has a first thickness and the second contact portion has a second thickness different from the first. This parameter variation allows each contact portion to be optimized for both strength and adaptability to local height conditions, resolving the contradiction between connection strength and adaptability.
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
The design enhances the quality and safety of battery modules by allowing close coupling of terminal portions, effectively overcoming height differences and ensuring reliable high-capacity battery packs.
Implementation Method 1
A battery module has a structure in which terminal portions of adjacent battery cells are closely connected to each other... a terminal connecting member provided with a stepped portion enabling a step difference to be overcome
Data Source
AI summary
A battery module includes a plurality of battery cells, each including terminal portions on a first surface thereof, the plurality of battery cells being aligned in a first direction; and a terminal connecting member configured to connect terminal portions of first and second battery cells of the plurality of battery cells that are adjacent to each other, and the terminal connecting member includes first and second contact portions spaced apart from each other to respectively come in surface contact with the terminal portions of the first and second battery cells, and a body portion connecting the first and second contact portions to each other.