Battery Pack Direct Terminal Connection Eliminates Relay Tabs
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Solution Overview
Problem
Existing battery pack designs require extra space for connecting relay tabs, leading to inefficiencies in space usage and potential disconnection due to stress from vibration or impact, and face challenges with dimension errors in electrode terminal positioning during assembly.
Innovation Solution
The battery pack design directly connects the electrode terminals of adjacent battery cells at the same height to each other and to the circuit board without using relay tabs, allowing for efficient space usage and reduced stress on the terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If relay tabs are used to connect electrode terminals of battery cells to the circuit board, then the battery cells can be electrically connected, but extra space is required for connecting the relay tabs and the assembly process becomes more complex
Solution Approach 1:
The invention extracts and eliminates the relay tab component from the battery pack structure. By directly connecting the electrode terminals of adjacent battery cells to each other and to the circuit board, the patent removes the intermediate relay tab element, thereby simplifying the overall structure and reducing assembly complexity while maintaining electrical connection functionality
Solution Approach 2:
The invention merges the function of the relay tab with the battery cell structure itself. The electrode terminals are positioned and connected directly without requiring separate connection components, combining the electrical connection function into the battery cell arrangement rather than requiring an additional relay tab component
2Reliability
If relay tabs are folded to connect battery cells, then electrical connection is achieved, but stress is applied to the folded portion causing potential disconnection due to vibration or impact
Solution Approach 1:
The invention removes the relay tab component entirely, eliminating the folded portion that was susceptible to stress and potential disconnection. By directly connecting electrode terminals without folding or intermediate components, the patent eliminates the weak point that caused reliability issues under vibration and impact
Solution Approach 2:
Instead of folding the relay tab to achieve connection, the invention inverts the approach by positioning electrode terminals to connect directly in their natural straight configuration. This reverses the conventional method of deformation-for-connection and achieves connection through direct alignment, eliminating stress concentration
3Adaptability or versatility
If battery cells are overlaid with terminals at different heights, then connection flexibility is provided, but dimension errors in electrode terminal positioning occur during assembly
Solution Approach 1:
The invention applies local quality by positioning electrode terminals at the same height specifically at the connection interface between adjacent battery cells. This localized uniformity in terminal height at critical connection points eliminates positioning errors while maintaining overall design flexibility through the direct connection arrangement
4Ease of manufacture
If extra space is allocated for relay tab connections, then assembly is facilitated, but the battery pack size increases reducing space efficiency
Solution Approach 1:
The invention extracts the relay tab component and its associated connection space requirements. By eliminating this intermediate component, the patent removes the need for extra space allocated for relay tab connections, thereby reducing overall battery pack volume while maintaining assembly feasibility through direct electrode terminal connections
Solution Approach 2:
The invention changes the dimensional arrangement by positioning electrode terminals at the same height in the vertical dimension, enabling direct horizontal connection between adjacent battery cells. This dimensional adjustment eliminates the need for vertical space accommodation of folded relay tabs, optimizing space utilization in the battery pack
Data Source
AI summary
A battery pack is disclosed. The battery pack includes one or more battery assemblies and a circuit board connected to the battery assemblies. The battery assembly includes first and second battery cells having the predetermined surfaces overlaid on each other. The first and second battery cells each have battery elements accommodated in a container thereof, and cathode terminals and anode terminals are provided at a same height as the predetermined surfaces at a same side. The cathode terminal and anode terminal of the first battery cell are adjacent respectively to the cathode terminal and anode terminal of the second battery cell.