Battery Pack Sensing Substrate Layout for Bus Bar Swelling Movement

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Solution Overview

Problem

Secondary battery packs face internal stress and potential damage due to volume expansion during charging and discharging, which can lead to positional movement of bus bars and accumulation of stress, affecting the sensing substrate's functionality.

Innovation Solution

A battery pack design featuring a sensing substrate with deformation accommodating spaces, including first and second deformation accommodating spaces, allows the substrate to flexibly deform and accommodate positional movement of bus bars, preventing stress accumulation and maintaining co-planarity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the sensing substrate is made rigid to maintain structural stability, then manufacturing precision and reliability are improved, but the substrate cannot accommodate positional movement of bus bars due to battery cell swelling, leading to stress accumulation and potential damage

Engineering Contradiction:

Improvesensing substrate durabilityVSAvoidaccommodation of bus bar positional movement

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The sensing substrate is divided into multiple regions: rigid main body portions for stable mounting and signal processing, and flexible deformation accommodating spaces with relaxed constraints that allow movement of bus bars during battery cell swelling. This segmentation enables different parts of the substrate to have different mechanical properties, resolving the contradiction between rigidity and adaptability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The substrate's mechanical parameters are varied spatially - the main body maintains high rigidity for structural stability, while specific regions incorporate deformation accommodating spaces with reduced constraint parameters that allow controlled flexibility. This parameter variation enables the substrate to simultaneously achieve reliability and adaptability.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If the sensing substrate is made flexible to accommodate bus bar movement, then adaptability is improved, but structural stability and manufacturing precision deteriorate

Engineering Contradiction:

Improveaccommodation of bus bar positional movementVSAvoidsubstrate structural stability

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The substrate is segmented into rigid main body portions that maintain manufacturing precision and structural stability, and flexible deformation accommodating spaces that provide adaptability. The segmentation allows each region to be optimized for its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the substrate have different mechanical qualities - the main body has high rigidity for precision, while localized deformation accommodating spaces have controlled flexibility. This local quality differentiation resolves the contradiction between overall structural stability and local adaptability.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If deformation accommodating spaces are introduced to the sensing substrate, then adaptability is improved, but device complexity increases

Engineering Contradiction:

Improveaccommodation of bus bar positional movementVSAvoidsubstrate structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The deformation accommodating spaces are implemented as simple segmented regions within the substrate layout, defined by relaxed constraint zones rather than complex mechanical structures. This segmentation approach adds adaptability while maintaining relatively simple device architecture.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The complexity is reduced by implementing deformation accommodation through parameter changes in the substrate's constraint distribution rather than through complex mechanical structures. The deformation accommodating spaces are defined by varying the rigidity parameter across different substrate regions.

Inventive Principle:

Principle #35Parameter changes

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 effectively reduces internal stress and prevents damage to the sensing substrate by allowing flexible deformation in response to battery cell swelling, ensuring stable connectivity and accurate state information collection.

Implementation Method 1

a part of the sensing substrate, which is for acquiring state information of battery cells, may be flexibly deformed to accommodate positional movement of bus bars due to volume expansion, such as swelling, of the battery cells

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS20230411716A1Battery pack

Publication Date: 2023.12.21 SAMSUNG SDI CO LTD

AI summary

A battery pack includes: a plurality of battery cells; and a sensing substrate configured to collect state information from the plurality of battery cells. The sensing substrate includes: a main body; branch portions connected to the main body and spaced apart from the sensing substrate such that first deformation accommodating spaces are formed between the main body and the branch portions; and ring units connected to the branch portions and forming second deformation accommodating spaces.