Battery Pack Connection Tab Layout for Compact Low-Resistance Routing
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Solution Overview
Problem
Existing battery packs for high-power devices like electric vehicles and hybrid vehicles face challenges in compact design, protection of connection tabs, and efficient signal transmission due to the need for multiple batteries and complex connections.
Innovation Solution
A battery pack design featuring a connection tab that extends into the valley between adjacent battery cells, providing protection and a reduced spatial height, along with a low-resistive signal transmission path, and a cell holder that accommodates battery cells with a circuit board for controlling charging and discharging operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the connection tab is extended to connect battery cells and circuit board, then electrical connection is achieved, but the connection tab becomes vulnerable to damage and occupies excessive space
Solution Approach 1:
The connection tab is nested within the valley region formed between adjacent battery cells. The tab extends into the existing space between cells rather than occupying external space, achieving protection while minimizing volume occupation.
Solution Approach 2:
The valley region between battery cells serves as an intermediary space that accommodates the connection tab. This intermediate zone provides both physical protection and spatial efficiency by utilizing the natural gap between adjacent cells.
2Power
If multiple battery cells are used to increase output capacity, then power output is improved, but the complexity of connections and space occupation increases
Solution Approach 1:
Multiple battery cells are arranged adjacently to form a unified pack structure. The connection tabs of multiple cells converge into shared valley regions, merging individual connection paths into a consolidated electrical architecture that reduces overall complexity.
Solution Approach 2:
The valley regions between adjacent battery cells serve multiple functions: they provide mechanical spacing, accommodate connection tabs, and facilitate electrical connections. This multi-functional design reduces the need for additional specialized components.
3Reliability
If the connection tab is made longer to reduce resistive design, then signal transmission is improved, but the tab becomes more exposed to damage
Solution Approach 1:
The connection tab is nested within the protective valley region formed by adjacent battery cells. This positioning allows the tab to achieve adequate length for low-resistive signal transmission while being physically protected by the surrounding cell structures.
Solution Approach 2:
The valley region, which could be seen as empty space, is converted into a protective enclosure for the connection tab. The same geometric feature that defines the cell arrangement also provides damage protection to the electrical connection.
Data Source
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AI summary
A battery pack includes at least two battery cells; a circuit board to control charging and discharging operations of the battery cells; and a connection tab electrically connected to the battery cells, extending towards the circuit board, and including a bent portion proximal to the battery cells and located within a battery area defined by the battery cells. A battery pack suitable for a compact type device is provided and a low-resistive design may be applied to the battery pack.