Battery Pack Electrode Tab Positioning via Case Protrusions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing battery module assembly method does not guarantee sufficient accuracy in positioning electrode tabs, leading to potential inaccuracies in welding and electrical connections.
Innovation Solution
A battery pack design featuring a case with protrusions that guide and secure electrode tabs, along with insulating members and restraining plates, ensures accurate positioning and secure welding of electrode tabs, enhancing assembly precision and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If battery cells are attached to the lower frame after electrode tabs are welded together, then assembly is simplified, but electrode tab positioning accuracy deteriorates
Solution Approach 1:
The protrusions are pre-formed on the lower frame before battery cell assembly. These protrusions create positioning recesses that guide and constrain the electrode tabs to predetermined positions during the welding process, ensuring accurate positioning is achieved before the cells are permanently attached to the frame.
Solution Approach 2:
The protrusions act as intermediary positioning elements between the lower frame and the electrode tabs. They provide a mechanical interface that ensures accurate relative positioning of the electrode tabs with respect to the lower frame during welding, without requiring complex fixtures or adjustment mechanisms.
2Productivity
If electrode tabs are welded together without precise positioning structures, then assembly process is faster, but welding accuracy and connection reliability deteriorate
Solution Approach 1:
The protrusions on the lower frame automatically guide the electrode tabs into the correct positions during assembly. The positioning recesses formed by the protrusions enable the electrode tabs to self-align and self-position at predetermined locations, eliminating the need for external positioning fixtures or complex alignment procedures, thus maintaining high assembly speed while ensuring welding accuracy.
Data Source
AI summary
A battery pack includes stacked battery cells, each battery cell including a first outer surface having an electrode tab protruding therefrom and a second outer surface that is a side surface intersecting the first outer surface, and a first case that surrounds the battery cells along the first outer surface and the second outer surface. An opening exposing the electrode tab is formed in the first case. The opening includes an inner surface that faces a side surface of all of the electrode tabs exposed through the opening and that is capable of abutting against the electrode tabs when the battery cells are inserted in the first case.