Battery Pack Cell Stacking and Tab Welding Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Battery packs formed by connecting cylindrical cells in series are not space-efficient, resulting in low energy density per unit volume and are inconvenient to use due to spacing between cells.
Innovation Solution
A battery pack design that includes a housing with a cell module of stacked cells, an adapter board, connecting strips, and a circuit board, where the tabs of the cells are welded onto the adapter board and connected to the connecting strips, which are then connected to the circuit board, allowing for close stacking and efficient use of space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cylindrical cells are connected in series with spacing between them, then the battery pack structure is simple and easy to assemble, but the space efficiency is low and energy density per unit volume is reduced
Solution Approach 1:
The patent transitions from horizontal side-by-side cell arrangement to vertical stacking arrangement, utilizing the vertical dimension to eliminate spacing waste. Multiple cells are stacked vertically with tabs extending outward, allowing connecting strips to connect adjacent cells in the stacking direction without requiring horizontal spacing, thereby significantly improving space efficiency and energy density.
Solution Approach 2:
The patent integrates the connecting strips directly with the cell tabs through welding, merging the connection function into the cell structure itself. The connecting strips are welded to the tabs of stacked cells, eliminating the need for separate mounting structures and reducing overall pack volume while maintaining electrical connectivity.
2Ease of manufacture
If cylindrical cells are arranged side by side with spacing, then the battery pack is easier to assemble, but the overall size increases and convenience of use decreases
Solution Approach 1:
The patent arranges cells in a vertical stacking configuration rather than horizontal placement, utilizing the vertical dimension to compact the battery pack structure. This stacking arrangement allows cells to be closely positioned without requiring horizontal spacing, reducing the overall pack volume while maintaining assembly simplicity through standardized connection interfaces.
Solution Approach 2:
The connecting strips are nested within the structural framework of the battery pack, with tabs extending from stacked cells and connecting strips welded between them. This nesting approach integrates the connection elements into the cell assembly itself, eliminating the need for separate external connection structures and reducing overall volume.
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 achieves a high energy density per unit volume and improves the convenience of use by allowing for close stacking of cells, enhancing both energy efficiency and usability.
Implementation Method 1
The first tab and the second tab are welded onto the adapter board
Data Source
AI summary
A battery pack includes: a housing, in which an accommodation space is made available; a cell module, accommodated in the accommodation space, and including a plurality of stacked cells, each cell comprises a cell housing, a first tab and a second tab, and the tabs extend out of the accommodation space; an adapter board, disposed on the cell module, where the first tab and the second tab are welded onto the adapter board; a circuit board, where the circuit board is arranged adjacent to the adapter board; a first connecting strip, one end is connected to the first tab, another end is connected to a positive input end of the circuit board; and a second connecting strip, one end is connected to the second tab, another end of is connected to a negative input end of the circuit board.