Battery Pack Tab Design for Circuit-Free Assembly
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Solution Overview
Problem
Existing battery packs face challenges in efficiently and safely connecting multiple battery cells without safety elements or protective circuits, leading to potential accidents like overcharging or over-discharging, and require complex assembly processes.
Innovation Solution
A battery pack design that includes a case with accommodating holes for battery cells at intervals, tabs with terminal coupling portions for electrical connection, and a terminal case with a fixing groove, allowing for simple electrical connection and fastening of battery cells without protective circuits, thereby preventing short circuits and facilitating assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery cells are connected using conventional methods with protective circuits and safety elements, then safety and reliability are improved, but device complexity and assembly difficulty increase
Solution Approach 1:
The invention extracts and eliminates protective circuits and safety elements from the battery pack design. The case structure with accommodating holes and tabs provides inherent safety through physical constraints and proper electrical connections without requiring additional protective circuitry, thus reducing device complexity while maintaining reliability
Solution Approach 2:
The battery pack structure itself provides safety functions through its design features. The case with accommodating holes ensures proper cell positioning and spacing, while tabs provide both electrical connection and structural support, making the system self-sufficient without external protective elements
2Reliability
If protective circuits and safety elements are included in the battery pack, then reliability is improved, but manufacturing cost and material usage increase
Solution Approach 1:
The invention removes protective circuits and safety elements from the design, reducing material consumption and manufacturing costs. The case structure with integrating accommodating holes and tabs provides the necessary safety and functional features through the base structure alone, eliminating the need for additional protective components
Solution Approach 2:
The case and tabs serve multiple functions simultaneously: structural support, electrical connection, cell positioning, and safety. This multi-functionality reduces the need for separate protective components, lowering material cost while maintaining reliability
3Reliability
If protective circuits are used to prevent overcharging and over-discharging, then reliability is improved, but device size and volume increase
Solution Approach 1:
The invention extracts protective circuits from the design, reducing the overall volume of the battery pack. Safety and proper operation are achieved through the structural design of the case with accommodating holes and tabs, which provide physical constraints and proper electrical connections without requiring additional space for protective electronics
Solution Approach 2:
The case structure integrates multiple functions including cell accommodation, positioning, electrical connection through tabs, and safety features into a single unified structure. This merging eliminates the need for separate protective circuits, reducing device volume while maintaining reliability
4Reliability
If complex assembly processes with protective circuits are used, then reliability is improved, but ease of manufacture and assembly ease decrease
Solution Approach 1:
The invention removes protective circuits and safety elements that complicate the assembly process. The simplified structure with case, accommodating holes, and tabs allows for straightforward assembly through direct placement and connection, improving ease of manufacture while maintaining safety through structural design
Solution Approach 2:
The battery pack is segmented into distinct functional components: case with accommodating holes for cell placement, tabs for electrical connection, and terminal case for external connection. This segmentation allows each component to be manufactured and assembled independently in a simple, systematic manner, improving ease of manufacture
Data Source
AI summary
A battery pack including: a plurality of battery cells; a case configured to accommodate the battery cells spaced from one another at an interval; and at least one tab configured to electrically connect the plurality of battery cells, and a terminal coupling portion is formed at a side of the tab.