Battery Sensing Block Structure to Prevent Electrode Lead Damage
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Solution Overview
Problem
Existing battery module designs face issues with electrode lead damage due to sharp corners in sensing blocks, and the injection molds used to create these blocks require high precision and have short replacement cycles due to wear.
Innovation Solution
A battery module structure with a sensing block featuring flat surfaces and stepped portions, along with an injection mold design that ensures smooth coupling and reduced wear, preventing electrode lead damage and extending mold life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the corner portions of the mold are smoothly connected to prevent sharp burrs, then electrode lead damage is prevented, but manufacturing precision requirements increase and mold replacement cycle shortens due to wear
Solution Approach 1:
The patent applies curvature by rounding the corner portions of the sensing block where the slit meets the front surface. This rounded corner structure prevents sharp burrs from forming during injection molding, thereby preventing electrode lead damage while avoiding the need for extremely precise mold mating. The curved transition distributes stress and eliminates the harmful sharp corner geometry.
2Object-affected harmful factors
If the corner portions of the mold are smoothly connected, then electrode lead damage is prevented, but mold durability decreases due to repeated contact and wear
Solution Approach 1:
By rounding the corner portions of both the sensing block and the corresponding mold cavities, the patent creates a self-aligning curved contact surface. This curved geometry distributes contact stress more evenly during repeated mold opening and closing cycles, reducing wear concentration at sharp corners and extending mold service life while maintaining the prevention of electrode lead damage.
3Object-affected harmful factors
If a rounded corner structure is used in the sensing block, then electrode lead damage is prevented, but device complexity increases
Solution Approach 1:
The patent merges the rounded corner feature directly into the injection molding process of the sensing block, integrating the protective geometry into the base manufacturing step. This approach avoids adding separate components or post-processing steps, maintaining structural simplicity while effectively preventing electrode lead damage through the integrated rounded corner design.
Data Source
AI summary
Provided is a structure of a battery module including: a battery cell including an electrode lead protruding and extending forward; a sensing block arranged in front of the battery cell and having a slit through which the electrode lead passes forward and rearward; and a bus bar mounted on a front portion of the sensing block and on one side in a width direction of the slit, wherein the electrode lead is bent toward one side in the width direction at a bent portion located forward of the slit and is connected to the bus bar, the sensing block includes a first flat surface, a second flat surface, and a stepped portion, and a boundary where the inner peripheral surface of the slit and the first flat surface meet is formed as a corner having an internal angle of 90 degrees or less.