Battery Pack Drawer Portion with Cutout Substrate
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Solution Overview
Problem
Conventional battery packs face challenges in maximizing volumetric efficiency due to unnecessary space caused by wall portions and non-linear wiring patterns, leading to increased design and production costs, as well as the need for custom circuit substrates for each battery configuration.
Innovation Solution
The battery pack design includes a connection substrate with cutouts to accommodate the wall portions of the battery cells, allowing for parallel arrangement and efficient wiring, and a connection member that enables the substrate to be connected and disconnected, allowing for the reuse of the substrate across different configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If wall portions are formed by bending the laminated film to contain battery elements, then the battery cell structure is stabilized, but unnecessary space is created in the drawer portion reducing volumetric efficiency
Solution Approach 1:
The connection substrate is nested within the drawer portion of the battery cell, with the substrate positioned inside the space defined by the wall portions. This nesting arrangement allows the substrate to occupy otherwise wasted space, eliminating empty volume while maintaining the structural stability provided by the wall portions.
Solution Approach 2:
The invention utilizes the vertical dimension within the drawer portion by positioning the connection substrate in the depth direction of the battery cell. Instead of allowing the drawer portion to be empty space, the substrate is placed in this third dimension, effectively using the available volume without interfering with the wall portions' stabilizing function.
2Reliability
If relay tabs are used to connect electrode terminals to the circuit substrate, then electrical connection is achieved, but the number of parts and production complexity increase
Solution Approach 1:
The connection substrate integrates multiple functions into a single component: it serves as both the electrical connection element (replacing relay tabs) and the circuit mounting substrate. The substrate directly connects to the electrode terminals and provides the circuit mounting surface, eliminating the need for separate relay tabs and reducing the total number of parts.
Solution Approach 2:
The connection substrate performs multiple functions simultaneously: it provides electrical connection between battery cells, serves as a mounting platform for circuits, and acts as a structural support element. This multi-functionality replaces what previously required multiple separate components, simplifying the overall device structure.
3Adaptability or versatility
If custom circuit substrates are designed for each battery pack configuration, then specific electrical requirements are met, but design and production costs increase
Solution Approach 1:
The connection substrate is designed as a universal component that can be used across different battery pack configurations. By standardizing the substrate design with consistent connection points and circuit mounting areas, the same substrate can serve multiple battery arrangements, eliminating the need for custom substrates for each configuration and reducing production costs.
Solution Approach 2:
The connection substrate is designed with modular connection points and standardized circuit mounting areas that can be configured for different battery arrangements. This segmentation allows a single substrate design to adapt to various electrical configurations through different connection patterns, maintaining versatility while using a standardized base design for cost-effective manufacturing.
Data Source
AI summary
A battery pack is provided that includes a plurality of batteries, a connection substrate being connected to the plurality of batteries, a circuit substrate for connecting an external electronic device, and a connection member for connecting the connection substrate and the circuit substrate. Each battery has a drawer portion for leading out a cathode terminal and an anode terminal provided at a same side of the battery. The drawer portion has wall portions standing against the drawer portion so that the side portions of the drawer portion are opposed each other. The plurality of batteries are arranged in row so that the drawer portion of the plurality of batteries face to a same direction. A part of the connection substrate is disposed on the drawer portion of the battery. The rim of the connection substrate is provided with cutouts to let the wall portions disposed therein.