Battery Pack Connection Tab Slit Design for Short Circuit Prevention
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Solution Overview
Problem
Existing battery packs face challenges in maintaining stability, preventing short circuits between connection tabs and bare cell ends, and enhancing welding strength between connection tabs and welding units.
Innovation Solution
A battery pack design featuring a connection tab with slits and bridges that cross each other, allowing for improved current flow management and reduced risk of short circuits, along with a welding unit that is grooved or embossed for enhanced adhesion and welding efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a connection tab is welded to the electrode unit of a bare cell, then electrical connection is established, but the connection tab may contact the upper end of the bare cell and cause a short circuit
Solution Approach 1:
The connection tab is divided into multiple body units with slits between them. This segmentation creates isolated welding zones that prevent the connection tab from contacting the bare cell upper end, eliminating the short circuit risk while maintaining electrical connection reliability through the distributed body units.
Solution Approach 2:
The slits act as intermediary spaces between the body units, creating a physical barrier that prevents direct contact between the connection tab and the bare cell upper end. This intermediary structure allows electrical connection through the body units while blocking the harmful contact path.
2Ease of manufacture
If the connection tab structure is simplified, then manufacturing is easier, but stability during overcharge or overdischarge cannot be ensured
Solution Approach 1:
The connection tab is segmented into multiple body units with slits, creating a structure that is both manufacturable and stable. The segmented design allows for controlled current paths that enhance stability during overcharge or overdischarge while maintaining ease of manufacture through a modular structure that can be produced using standard welding techniques.
Solution Approach 2:
Different regions of the connection tab have different properties: the body units provide electrical connection and structural integrity, while the slits provide isolation and stability control. This local differentiation allows the structure to meet both manufacturing ease and operational stability requirements.
3Strength
If welding area is increased, then welding strength is improved, but current flow during welding may increase causing excessive heat
Solution Approach 1:
The welding area is segmented into multiple smaller welding zones corresponding to the body units. This segmentation distributes the current flow across multiple points, preventing excessive heat generation while maintaining overall welding strength through the cumulative effect of multiple welds.
Solution Approach 2:
Instead of one large welding area, multiple partial welding zones are used. Each welding zone applies a portion of the total welding action, distributing the thermal load while achieving the required overall welding strength through the combination of multiple welds.
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 enhances stability by rapidly blocking current during overcharge or discharge, prevents short circuits, and increases welding strength, thereby improving the overall efficiency and reliability of the battery pack.
Implementation Method 1
The welding unit may be connected to the electrode unit of the bare cell by resistance welding
Data Source
AI summary
There is provided a battery pack with improved stability. The battery pack includes a plurality of bare cells including electrode units and arranged in a direction, a holder case configured to accommodate the plurality of bare cells, and a connection tab including a body unit electrically connected to the plurality of bare cells, a slit unit positioned in each of the electrode units of the plurality of bare cells, and at least one welding unit positioned to be adjacent to the slit unit and welded to the electrode unit of the bare cell. The slit unit includes first and second slits separated from each other by a certain distance, first and second bridges respectively provided between ends of the first and second slits, and a welding slit that crosses one point of each of the first and second slits. In the battery pack, one of the first and second bridges is formed to be stepped so that it is possible to rapidly and easily block flow of a current when over-charge or over-discharge occurs. Therefore, stability of the battery pack may improve.