Battery Pack Lead Plate Segmentation for Low Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery packs face issues with high electrical resistance due to lead plate configurations, leading to inefficiencies in high current discharges, unreliable connections, and difficulty in accommodating design changes for varying battery numbers.
Innovation Solution
A battery pack design featuring a battery block with batteries arranged vertically and horizontally, connected by lead plates that form both parallel and series configurations without bending, allowing for low resistance connections and easy adjustment of battery numbers without altering the circuit board size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lead plates are bent 180° to connect batteries in parallel, then connection is achieved, but electrical resistance increases and connection reliability decreases
Solution Approach 1:
The lead plate is segmented into multiple sections with slits that allow controlled bending at specific locations. This segmentation enables the lead plate to connect multiple batteries while maintaining structural integrity and reducing stress concentration, thereby improving connection reliability and reducing electrical resistance.
Solution Approach 2:
Instead of bending the entire lead plate 180° as a single unit, the invention inverts the approach by creating multiple small bends at slit locations. This distributes the bending stress and creates a more reliable connection with lower electrical resistance compared to a single large bend.
2Ease of manufacture
If lead plates are bent 180° to connect to circuit board, then connection is achieved, but lead plates and batteries easily become disconnected
Solution Approach 1:
The lead plate is pre-formed with slits and interconnect wiring projections during manufacturing. This preliminary action ensures that the bending and connection geometry is optimized before assembly, making the connection process easier while maintaining high reliability and preventing disconnection during use.
3Power
If number of parallel connected batteries is increased, then output current is increased, but circuit board size must be increased
Solution Approach 1:
The lead plate serves multiple functions: it connects batteries in parallel, provides structural support, and houses interconnect wiring projections for circuit board connection. This multi-functionality allows increased battery capacity without proportionally increasing circuit board size, as the lead plate itself manages the increased connectivity requirements.
4Ease of operation
If slit is provided in lead plate to allow bending, then bending is facilitated, but electrical resistance becomes significant
Solution Approach 1:
The slit is provided only in specific local regions of the lead plate where bending is required, while the main current-carrying paths remain intact. This localized slitting facilitates bending without significantly increasing electrical resistance, as the current flows through the undamaged portions of the lead plate.
Data Source
AI summary
A battery pack provided with a battery block (3), a case (2), and a circuit board (4). The battery block (3) has a plurality of batteries (1) lined up in a horizontal row with the same orientation, and lead plates (5) connect to terminals of those batteries (1) to form a parallel unit (6). A plurality of parallel units (6) are stacked in the vertical direction with a different orientation, and battery terminals are connected by lead plates (5) in the vertical direction to connect parallel units (6) in series. Lead plates (5) have projections (10) which protrude horizontally beyond the confines of the battery block (3) and connect with the circuit board (4), and the battery block (3) and circuit board (4) are connected as a unit.