Lithium Battery Unit Set Bus Bar Stacking Stability
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Solution Overview
Problem
Existing lithium secondary battery systems face challenges in firmly and stably stacking pouch units for high-output applications, ensuring reliable connections, preventing overheating, overcurrent flow, and maintaining uniform temperature distribution during charging and discharging.
Innovation Solution
A lithium secondary battery unit set with a bus bar configuration that includes end frames, main frames with tab support parts, and bus bars for direct connection of lithium secondary batteries, along with an overcurrent circuit breaker and thermal management using thermal pads to maintain uniform temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If pouch units are stacked for high-output applications, then voltage and capacitance can be increased, but the stacking structure becomes unstable and connections become unreliable
Solution Approach 1:
The battery system is divided into multiple pouch units that can be independently stacked and connected. Each pouch unit maintains its structural integrity while being part of a larger modular assembly, allowing stable stacking for high-output applications without compromising individual connection reliability
Solution Approach 2:
The patent transitions from planar battery arrangements to three-dimensional stacking configurations. By utilizing vertical stacking and multi-layer arrangements, the system achieves higher voltage and capacitance output while maintaining connection stability through structured support frames and organized tab connections
2Power
If multiple lithium secondary batteries are connected in series to increase voltage, then power output increases, but overcurrent flow becomes a risk during charging and discharging
Solution Approach 1:
Overcurrent circuit breakers are introduced as intermediary protective devices in the electrical circuit. These breakers are strategically placed to detect and interrupt excessive current flow, protecting the series-connected batteries from overcurrent damage while allowing normal high-voltage operation
Solution Approach 2:
Protective circuit boards and circuit breakers are pre-installed in the battery system to prevent overcurrent issues before they occur. These devices are configured to automatically respond to abnormal current conditions, breaking the circuit before damage can happen to the high-voltage battery configuration
3Quantity of substance
If batteries are densely stacked to improve space utilization, then energy density increases, but temperature distribution becomes non-uniform causing overheating
Solution Approach 1:
Thermal pads are introduced as intermediary thermal management components between adjacent battery pouches. These pads facilitate heat transfer and distribution across the battery stack, ensuring uniform temperature distribution even in densely packed configurations and preventing localized overheating
Solution Approach 2:
The patent employs phase change materials or thermal pads that utilize phase transition properties to manage heat flow. These materials absorb and release heat during phase transitions, actively regulating temperature distribution across densely stacked batteries and maintaining thermal uniformity
4Reliability
If electrode tabs are directly connected to terminals through sealing surface, then electrical connection is established, but electrical short between case and electrode tabs occurs
Solution Approach 1:
Sealing tabs are introduced as intermediary components between the electrode tabs and the case sealing surface. These sealing tabs provide electrical insulation while maintaining mechanical connection, preventing direct contact between conductive electrode tabs and the case structure, thereby eliminating electrical short risks
Solution Approach 2:
The sealing tape or sealing tab is a simple, easily replaceable component that provides critical insulation function. This disposable-like component is designed to be applied during assembly and can be replaced if needed, providing reliable electrical isolation without complicating the overall battery structure
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 solution enables stable and reliable stacking of lithium secondary batteries, prevents overheating and overcurrent issues, and ensures uniform temperature distribution, enhancing the performance and lifespan of high-output lithium secondary battery systems.
Implementation Method 1
making temperature distribution of stacked batteries uniform
Data Source
AI summary
The present invention relates to a lithium secondary battery unit set where a plurality of lithium secondary batteries are stacked, and a lithium secondary battery set including a plurality of lithium secondary battery unit sets. The present invention relates to a lithium secondary battery unit set with a bus bar and a lithium secondary battery set with a bus bar. The lithium secondary battery unit set with a bus bar: accommodates and protects a plurality of lithium secondary batteries comprising a pouch and an electrode tab; facilitates the changes of voltage and capacity as the stacked structure of the lithium secondary batteries becomes free; prevents the flow of overcurrent during charging and discharging; and enables uniform temperature distribution of the stacked batteries.