Battery Pack Bus Bar Bent Tabs Composite Materials
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Solution Overview
Problem
Existing battery packs face challenges in efficiently connecting multiple secondary cells in series and parallel configurations, leading to issues with durability and contact resistance under external impacts.
Innovation Solution
The battery pack employs a bus bar system with bent terminal connection tabs and a reinforcement bar made of different conductive materials, such as nickel and aluminum, to enhance durability and reduce contact resistance by absorbing external impacts and maintaining electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple secondary cells are connected in series and parallel configurations, then the power and capacity of the battery pack increase, but the contact resistance increases and durability decreases under external impacts
Solution Approach 1:
The bus bar is constructed as a composite structure with a nickel-based corrosion-resistant layer and an aluminum-based high-conductivity layer. This composite material approach simultaneously achieves high electrical conductivity, corrosion resistance, and mechanical strength, resolving the contradiction between power transmission capability and connection durability under external impacts
Solution Approach 2:
The terminal connection tabs are designed with bent shapes rather than straight configurations. This curvature allows the tabs to flex and absorb external impacts elastically, preventing brittle failure and maintaining reliable electrical connections even when subjected to mechanical stress during battery pack assembly and operation
2Reliability
If terminal connection tabs are made rigid for stable electrical connection, then electrical conductivity is maintained, but the connection becomes vulnerable to external impacts and durability decreases
Solution Approach 1:
The terminal connection tabs incorporate bent shapes that provide elastic flexibility. This allows the tabs to deform under external impacts and return to their original position, maintaining stable electrical connections while resisting mechanical damage from impacts during assembly and operation
3Reliability
If bus bar material is selected for high electrical conductivity, then contact resistance decreases, but corrosion resistance and mechanical strength may be compromised
Solution Approach 1:
The bus bar employs a composite structure combining nickel (corrosion-resistant) and aluminum (high-conductivity, lightweight). The nickel layer provides corrosion resistance and structural strength, while the aluminum layer delivers high electrical conductivity and reduced weight, achieving optimal balance among all three requirements
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 solution improves the battery pack's durability by absorbing external impacts and decreases contact resistance, ensuring reliable electrical connections and enhanced performance in series and parallel cell configurations.
Implementation Method 1
a reinforcement bar mounted on the bus bar body and including a conductive material different from that of the bus bar body
Implementation Method 2
at least one bus bar including a plurality of terminal connection tabs respectively connected with the first electrode terminals or the second electrode terminals of the plurality of cells to electrically connect the plurality of cells
Data Source
AI summary
Disclosed is a battery pack, including: a plurality of cells each provided with first and second electrode terminals and arranged such that the plurality of cells overlap in a first direction; and at least one bus bar including a plurality of terminal connection tabs connected with the first electrode terminals or the second electrode terminals of the plurality of cells to electrically connect the plurality of cells, in which the terminal connection tabs are bent at least one time in a region extending to the first electrode terminals or the second electrode terminals of the plurality of cells, thereby improving durability of the battery pack.