Battery Pack Electrode Tab Load Reduction
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Solution Overview
Problem
The existing battery pack designs face issues with fatigue fracture and joint separation of electrode tabs due to deformation of busbar modules caused by battery expansion and contraction, leading to increased load on electrodes and potential damage.
Innovation Solution
A battery pack design that includes multiple batteries with electrodes protruding from both ends, a substrate with insertion holes, and a fixing plate arranged between adjacent batteries, which reduces the load on electrodes by allowing the busbar modules to move with the batteries without being fixed to end plates, thereby minimizing position offset and stress on the electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If busbar modules are fastened to both end plates to prevent deformation, then structural stability is improved, but electrode tabs experience increased load and position offset due to battery expansion and contraction
Solution Approach 1:
The battery pack structure is segmented into multiple independent battery units, each with its own busbar module and electrode tabs. This segmentation allows each battery unit to expand and contract independently without transmitting stress to adjacent units, reducing the load on individual electrode tabs while maintaining overall structural stability through the modular arrangement.
2Shape
If busbar modules are fastened to both end plates, then deformation of busbar modules is limited, but position offset between electrode tabs and slits increases during battery expansion and contraction
Solution Approach 1:
The patent employs flexible connection structures between the busbar modules and end plates, allowing the busbar modules to move slightly with battery expansion and contraction. This flexibility accommodates position offset between electrode tabs and slits while preventing excessive deformation of the busbar modules, resolving the contradiction between maintaining shape and allowing positional adjustment.
3Strength
If busbar modules are fastened to both end plates, then mechanical support is improved, but fatigue fracture and joint separation of electrode tabs occur due to repeated stress
Solution Approach 1:
The patent transitions from a static fastening system to a dynamic one where busbar modules can move with battery expansion and contraction. This dynamic design allows the system to adapt to changing dimensions during charge-discharge cycles, reducing repeated stress on electrode tabs and preventing fatigue fracture and joint separation while maintaining adequate mechanical support.
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
This design effectively reduces the load on electrodes during battery expansion and contraction, minimizing fatigue fracture and joint separation risks while allowing busbar modules to move with the batteries, and provides a cooling effect using an aluminum fixing plate.
Implementation Method 1
provides a cooling effect using an aluminum fixing plate
Data Source
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AI summary
A battery pack is provided which enables a reduction of a load on the electrodes which occurs with expansion or contraction of the batteries. Multiple batteries (21-26) have electrode tabs (202) protruding from both ends, and are stacked in a stacking direction (D1) orthogonal to a protrusion direction (D2) of the electrode tabs (202). Busbar modules (41, 42) are jointed to the electrode tabs (202) and comprise busbars (402) for connecting the batteries (21-26). An aluminum plate (5) is arranged between batteries (23, 24) of the multiple batteries (21-26) which are adjacent to a center. This aluminum plate (5) and the busbar modules (41, 42) are fixed.