Battery Module Tab-Busbar Rib Fixation in Narrow Cell Spacing
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Solution Overview
Problem
The challenge in designing a rechargeable battery module is maintaining adherence and stable fixation of tabs and busbars when the space between adjacent core packs is narrow, making it difficult to form guide bosses and use screws or bolts effectively.
Innovation Solution
The module incorporates a holder with internal and external rib members that are independently spaced and integrally formed, allowing for the secure fixation of tabs and busbars through bent inner and outer lateral portions, ensuring adherence and stability even in tight spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If core packs are disposed near or together with each other in a horizontal direction to provide large capacity, then the battery capacity is improved, but the space between core packs becomes narrow making it difficult to form guide bosses and use screws or bolts
Solution Approach 1:
The fixing structure is segmented into multiple rib members (internal rib member and external rib member) that are independently spaced. This segmentation allows the fixing function to be distributed across multiple smaller structural elements that can be formed even in narrow spaces between core packs, resolving the contradiction between high capacity (tight spacing) and ease of manufacture.
Solution Approach 2:
The invention transitions from a conventional single-plane fixing approach to a multi-dimensional rib structure. The internal and external rib members are arranged in different spatial dimensions and orientations, creating a three-dimensional fixing network that can accommodate tabs and busbars effectively even when horizontal space is limited between core packs.
2Volume of stationary object
If the space between core packs is narrow, then the battery module density is improved, but it becomes difficult to maintain adherence and stable fixation of tabs and busbars
Solution Approach 1:
The internal rib member and external rib member are integrally formed as a unified structure, combining multiple fixing functions into a single integrated component. This merging ensures that tabs and busbars are simultaneously constrained by both internal and external ribs, maintaining reliable adherence and stable fixation even in the narrow spaces between densely packed core packs.
Solution Approach 2:
The fixing structure employs a nested arrangement where the internal rib member is positioned within the space defined by the external rib member. This nested configuration allows the fixing system to operate effectively in the limited space between core packs while maintaining both adherence and stability of the electrical connections.
Data Source
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AI summary
A rechargeable battery module includes a holder configured to accommodate battery cells spaced in from each other in a first direction and a second direction crossing the first direction; tabs configured to electrically connect the battery cells to each other, at least one of the tabs having an inner planar portion and an inner lateral portion bent from the inner planar portion and fixed to a side of the holder; and busbars configured to connect the tabs to a battery management system. At least one of the busbars has an outer lateral portion connected to the inner lateral portion of the tab and an outer planar portion bent from the outer lateral portion and spaced from the inner planar portion. The holder includes a rib configured to fix at least one of the inner lateral portion of the tab and the outer lateral portion of the busbar.