Battery Pack Connection Plate Layout for High Current Stability
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Solution Overview
Problem
Battery packs for transportation face limitations in increasing maximum allowable current due to high electrical resistance and structural instability caused by vibrations and impacts, which restricts the size and shape of internal components.
Innovation Solution
A battery pack design featuring connection plates with strategically placed through-holes to minimize electrical resistance and a cell frame with protrusions for stable mounting, along with a battery management system module for controlled charging and discharging, enhances the stability and efficiency of electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the size of bus bar or metal plate is increased to reduce electrical resistance and increase allowable current, then the maximum allowable current is improved, but the battery pack size and device complexity increase
Solution Approach 1:
The connection plate is segmented into multiple sections with through-holes at strategic positions, allowing current to flow through multiple parallel paths. This segmentation reduces electrical resistance without requiring a single large solid plate, thus maintaining compact battery pack size while increasing allowable current capacity
Solution Approach 2:
Through-holes are positioned at specific locations on the connection plate where they create localized current pathways. This local quality approach optimizes the distribution of current flow, reducing overall electrical resistance while maintaining a compact connection plate structure that fits within the battery pack volume constraints
2Volume of stationary object
If internal components are tightly mounted to save space, then the battery pack volume is reduced, but connection or coupling between internal components is released or components are separated due to vibration and impact
Solution Approach 1:
The cell frame protrusions are designed in advance to fit into corresponding recesses on the connection plates and battery cells. This preliminary action ensures that components are pre-aligned and pre-positioned correctly, preventing separation under vibration and impact while maintaining compact spacing between components
Solution Approach 2:
The cell frame acts as an intermediary structure with protrusions that mechanically couple the connection plates to the battery cells. This intermediary mechanism provides stable mechanical connection without requiring excessive mounting space, thus maintaining compact battery pack volume while ensuring reliable component coupling under vibrational conditions
Data Source
AI summary
A battery pack according to the present disclosure includes: a plurality of battery cells each including electrode terminals on both end portions thereof; at least two connection plates that are electrically conductive and configured to electrically connect the plurality of battery cells; and a cell frame having a plurality of hollow holes surrounding at least a portion of each of the plurality of battery cells and configured to allow the connection plates to be mounted outside the cell frame. The cell frame including at least two first fixing protrusions protruding outward to respectively pass through at least two through-holes of the connection plates. At least one of the at least two connection plates includes at least two through-holes spaced apart from one another in a current flowing direction.