Hexahedral Battery Pack Case with Coupling Grooves
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Solution Overview
Problem
Secondary batteries used in bulk-sized power sources for vehicles require cost-effective assembly, prevention of electrolyte leakage, and reduction of current leakage, while existing solutions increase manufacturing costs and complexity.
Innovation Solution
A secondary battery design featuring a hexahedral case with inwardly recessed coupling grooves for positive and negative electrodes, allowing for easy series or parallel connection without external bus bars, and an insulation member to prevent electrical shorts, along with a cap plate for sealing and safety venting, which reduces assembly time and material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external bus bars are used for electrical connection between batteries, then reliable electrical connection is achieved, but manufacturing cost and device complexity increase
Solution Approach 1:
The patent merges the electrical connection function into the case structure itself by forming coupling grooves directly on the case surface. The positive and negative electrode connections are integrated into the case body, eliminating the need for separate external bus bars and reducing overall device complexity while maintaining reliable electrical connection.
Solution Approach 2:
The case structure serves multiple functions: it provides mechanical protection, structural support, and electrical connection pathways. The coupling grooves formed on the case enable both mechanical assembly and electrical connection between adjacent batteries, making the case a multi-functional component that reduces the number of separate parts needed.
2Reliability
If multiple separate components are used for assembly, then functional requirements are met, but assembly time and manufacturing cost increase
Solution Approach 1:
The patent combines multiple functional components into an integrated case structure. The coupling grooves for electrical connection are formed directly on the case body during case manufacturing, eliminating the need for separate connection components and reducing assembly steps. This integration significantly reduces assembly time while maintaining all necessary functional requirements.
3Ease of manufacture
If coupling grooves are formed on case surface, then assembly ease and manufacturing cost reduction are achieved, but case structural strength may be compromised
Solution Approach 1:
The coupling grooves are formed on the case surface during the case manufacturing process itself, before final assembly. This preliminary formation of grooves through molding or machining ensures that the case maintains its structural integrity while being prepared for easy assembly. The grooves are designed with appropriate dimensions and positioning to facilitate assembly without compromising overall case strength.
Data Source
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AI summary
A secondary battery including a case having an opening; an electrode assembly housed in the case; at least one current collector coupled to an uncoated portion of the electrode assembly and forming an electrode terminal, wherein the case has a coupling groove recessed toward the at least one current collector; and a cap plate coupled to seal the opening of the case.