Battery Pack Lead Reinforcement for Vibration and Cell Swelling
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Solution Overview
Problem
Secondary batteries used in mobility applications face challenges in maintaining safety and structural integrity due to vibrations and cell swelling, which can damage leads and compromise the battery pack's performance.
Innovation Solution
A battery pack design incorporating a reinforcing bracket coupled to the lead and cross-beams, featuring a corrugated structure to enhance rigidity and prevent damage from vibrations and swelling, with components welded for stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the lead is made flexible to accommodate battery cell swelling, then the battery can maintain cell expansion, but the lead becomes vulnerable to vibration damage
Solution Approach 1:
The lead is divided into multiple segments along its length, with each segment capable of independent movement. This segmentation allows the lead to accommodate battery cell swelling through controlled segmental displacement while maintaining overall structural integrity and resistance to vibration damage.
2Reliability
If the lead is rigidly fixed to prevent vibration damage, then the lead becomes more durable, but the battery cell swelling is constrained
Solution Approach 1:
The lead incorporates dynamic elements such as flexible joints or movable connection points that allow controlled movement in response to battery cell swelling while maintaining sufficient rigidity to resist vibration damage. This dynamic design enables the lead to adapt its stiffness characteristics based on operational conditions.
3Strength
If the reinforcing bracket is added to strengthen the lead, then the structural integrity is improved, but the device complexity increases
Solution Approach 1:
The reinforcing bracket is integrated with existing battery pack structural components such as the housing or mounting brackets, combining multiple functions into a single element. This merging approach provides the necessary lead strengthening while minimizing the increase in overall device complexity.
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
The design effectively prevents lead damage and ensures uniform pressure distribution, enhancing the battery pack's structural integrity and safety by reinforcing the lead and cross-beams against vibrations and swelling.
Implementation Method 1
The reinforcing bracket may be coupled to the lead by a spot welding.
Implementation Method 2
The lead may include a corrugated structure that overlaps with the reinforcing bracket.
Implementation Method 3
The reinforcing bracket may include a corrugated structure.
Data Source
Figure 1
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AI summary
A battery pack according to embodiments of the present disclosure is provided. The battery pack includes a pack housing including a base plate and sidewalls; first and second cross-beams disposed on the pack housing, and spaced apart in a first direction parallel to a mounting surface of the base plate and extending in a second direction parallel to the mounting surface of the base plate; a battery cell assembly interposed between the first and second cross-beams; a lead coupled to the sidewalls and covering the battery cell assembly; and a reinforcing bracket coupled to the lead and extending along the first direction.