Secondary Battery Tab Bridge Modular Insulating Body
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Solution Overview
Problem
Secondary batteries face challenges in providing sufficient output and capacity for high-power applications like electric vehicles, requiring modular designs that maintain structural integrity and prevent deformation due to temperature changes during molding.
Innovation Solution
A modular secondary battery design featuring a protection module package with a tab bridge connecting spaced-apart insulating body blocks, integrating a circuit portion for charge/discharge paths and protection, and a flexible circuit board for electrical connections, which suppresses torsional moments and enhances structural stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a modular battery design is used to provide sufficient output and capacity for high-power applications, then the battery can meet high-power requirements, but structural deformation may occur due to temperature changes during molding
Solution Approach 1:
The insulating body is divided into multiple blocks (first insulating block, second insulating block, third insulating block) that are spaced apart from each other. This segmentation allows each block to be molded independently, reducing thermal stress and preventing deformation while still providing the necessary structural support for high-power applications.
Solution Approach 2:
Tab bridges are introduced as intermediary components connecting the spaced-apart insulating blocks. The tab bridges serve as mediators that maintain structural integrity and electrical connectivity between blocks, allowing the modular design to achieve both high power output and structural stability.
2Stability of the object's composition
If insulating body blocks are spaced apart to prevent deformation, then structural stability is improved, but electrical connectivity and structural rigidity may be compromised
Solution Approach 1:
Tab bridges function as intermediary components that span the gaps between spaced-apart insulating blocks. These tab bridges restore structural rigidity by mechanically connecting the blocks while maintaining the spacing that prevents molding deformation. The tab bridges transfer and distribute mechanical loads, ensuring overall structural strength.
Solution Approach 2:
The structure combines different materials with complementary properties: insulating blocks provide electrical insulation and structural support, while tab bridges (made of conductive material) provide both mechanical connection and electrical connectivity. This composite approach allows the system to achieve both structural rigidity and electrical functionality.
3Stability of the object's composition
If a tab bridge connects spaced-apart insulating blocks, then structural integrity is maintained, but manufacturing complexity increases
Solution Approach 1:
The tab bridge performs multiple functions simultaneously: it provides mechanical connection between insulating blocks, maintains structural integrity, and establishes electrical connectivity. By merging these functions into a single component, the design reduces the number of separate parts needed and simplifies the overall assembly process despite the spaced-apart block configuration.
Solution Approach 2:
The tab bridge is designed as a multi-functional component that serves as both a structural connector and an electrical conductor. This universality allows a single component to address multiple requirements (mechanical support, structural integrity, electrical connectivity), thereby reducing manufacturing complexity compared to using separate components for each function.
Data Source
AI summary
A secondary battery includes a protection module package including a tab bridge, an input/output terminal, and an insulating body that includes a middle block and side block, the middle block having the input/output terminal therein, the side block being spaced apart from the middle block, and the tab bridge connecting the middle block to the side block; and a bare cell including an electrode that is electrically connected to the tab bridge.