Battery Module Terminal Relocation for Overcharge Safety
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Solution Overview
Problem
Existing battery modules face instability and safety risks due to overcharge-induced swelling and potential fires in lithium polymer batteries, with current solutions either having lower performance or increasing manufacturing complexity and cost.
Innovation Solution
A battery module design where the terminal and sensing terminal are relocated from the outer to the inner side of the electrode tab and bonded by welding, allowing for easy breakage of the electrode tabs during overcharge, enhancing rigidity and power blocking capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the terminal and sensing terminal are positioned at the outer side of the electrode tab, then the battery module structure is simpler, but the electrode tab cannot be easily broken to block power during overcharge
Solution Approach 1:
The patent inverts the conventional positioning by placing the terminal and sensing terminal at the inner side of the electrode tab instead of the outer side. This inversion enables the electrode tab to be easily broken by external force to block power during overcharge, while the terminal remains connected through the broken tab. The sensing terminal positioned at the inner side can still detect voltage effectively.
Solution Approach 2:
The patent segments the electrode tab into multiple portions, with the terminal and sensing terminal connected to different segments. This segmentation allows the electrode tab to be broken at specific locations while maintaining electrical connection through the terminal, enabling safety functionality without requiring complete tab failure.
2Strength
If the terminal and sensing terminal are bonded by welding, then rigidity is increased, but manufacturing complexity increases
Solution Approach 1:
The patent merges the terminal and sensing terminal into a single integrated component that is welded to the electrode tab as one unit. This combined structure increases rigidity and structural strength while simplifying the manufacturing process by reducing the number of separate welding operations needed compared to attaching separate terminal and sensing terminal components.
3Reliability
If the electrode tab is designed for easy breakage, then power blocking capability is improved, but structural strength is reduced
Solution Approach 1:
The patent applies local quality by creating a specific weak section or stress concentration point at a designated location on the electrode tab. This localized weakness enables controlled breakage at that specific point while maintaining the overall structural strength and integrity of the remaining electrode tab portions that still need to support normal operational loads.
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 effectively prevents power flow and reduces risks of gas generation, fires, and explosions during overcharge by ensuring easy breakage of electrode tabs, while maintaining manufacturing simplicity and cost-effectiveness.
Implementation Method 1
bonding the terminal and the sensing terminal to each other by welding to increase rigidity
Data Source
AI summary
Provided is a battery module in which at least one battery cell including an electrode tab including an anode tab and a cathode tab is stacked, including: a sensing assembly installed in a space between the anode tab and the cathode tab at a side of the battery module at which the electrode tab is positioned; and a terminal installed at the side of the battery module at which the electrode tab is positioned and connected to each of the electrode tabs of the battery cells positioned at the outermost portions, wherein the terminal is bonded and connected to a surface positioned at an inner side of the battery module in both sides of the anode tab and the cathode tab.