Battery Pack Barrier Wall and Traversing Tab Design
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Solution Overview
Problem
Existing battery packs face challenges in preventing short-circuits during the welding process of conductive tabs connecting battery cells to a protective circuit module.
Innovation Solution
Incorporating a barrier wall within the battery pack case, positioned between the battery cells and the case, and a traversing tab that electrically connects outermost battery cells, while maintaining a plate shape and throughholes to prevent short-circuits, and using conductive tabs like nickel, copper, or aluminum to connect cells in series.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive tabs are used to connect battery cells to the protective circuit module, then electrical connection is achieved, but short-circuit risk increases during welding process
Solution Approach 1:
The patent introduces a barrier wall as an intermediary component between the conductive tabs and the battery cells. This barrier wall physically separates the conductive tabs during the welding process, preventing unintended electrical contact and short-circuits while still allowing the tabs to be electrically connected to the battery cells through controlled pathways.
Solution Approach 2:
The barrier wall is designed with multiple throughholes that segment the wall structure, allowing selective passage of conductive tabs while maintaining isolation in other areas. This segmentation enables the barrier wall to provide targeted protection against short-circuits while permitting necessary electrical connections through the throughholes.
2Reliability
If barrier wall is added to prevent short-circuits, then safety is improved, but device complexity increases
Solution Approach 1:
The barrier wall serves multiple functions simultaneously: it acts as a physical barrier to prevent short-circuits, provides structural support within the battery pack, and guides the positioning of conductive tabs. By combining these functions into a single component, the patent reduces the need for additional separate parts, thereby limiting the increase in device complexity.
Solution Approach 2:
The barrier wall is designed with a porous structure containing multiple throughholes. This porous design allows the barrier wall to maintain its protective function while enabling necessary electrical connections and reducing material usage. The throughholes integrate the barrier wall into the existing battery pack structure without requiring additional components.
Data Source
AI summary
A battery pack is disclosed. In one aspect, the battery pack includes a plurality of battery cells electrically connected to each other and comprising first and second outermost battery cells positioned at opposite ends thereof and a case accommodating the battery cells. The battery pack also includes a barrier wall formed between the battery cells and the case and a traversing tab positioned between the case and the barrier wall and electrically connecting the first and second outermost battery cells. At least one embodiment can facilitate a welding process while preventing a conductive tab connecting battery cells to a protective circuit module from being short-circuited.