Bent Connection Plate Layout for High-Density Battery Packs
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Solution Overview
Problem
Conventional battery packs face limitations in energy density due to the need for separate space for welding metal plates, which restricts the number of cylindrical battery cells and increases the dead space in the module housing.
Innovation Solution
A battery pack design featuring connection plates with body portions mounted at the upper or lower portions of cylindrical battery cells, where the connection portions protrude and bend to contact each other, eliminating the need for separate connection spaces within the module housing, and incorporating a rib structure for mechanical rigidity and heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a plurality of battery modules are closely arranged in the front and rear direction, then the number of battery modules accommodated increases, but a separate space for welding metal plates must be provided, creating dead space that limits further cell inclusion and deteriorates energy density
Solution Approach 1:
The connection plate is integrated directly into the module housing structure, merging the connection function with the housing structure. This eliminates the need for separate connection spaces and welding operations, thereby removing dead space and allowing more battery cells to be accommodated in the limited volume.
Solution Approach 2:
The connection plate is extracted from being a separate welded component and repositioned as an integrated structural element of the module housing. This extraction eliminates the need for separate welding spaces and reduces the overall housing complexity while maintaining electrical connection functionality.
2Reliability
If separate space is provided for welding metal plates, then electrical connection between battery modules is achieved, but dead space is created that reduces the number of battery cells that can be accommodated
Solution Approach 1:
The connection plate is merged with the module housing structure, combining the electrical connection function with the mechanical housing structure. This integration eliminates separate welding spaces while maintaining reliable electrical connections between battery modules, thereby reducing dead space volume.
Solution Approach 2:
The module housing structure is given multiple functions: it provides mechanical protection, structural support, and electrical connection pathways. The connection plate serves dual purposes as both a structural element and an electrical conductor, eliminating the need for separate welding components and spaces.
3Reliability
If metal plates are welded to connect battery modules, then electrical connection is established, but manufacturing complexity and cost increase due to separate welding processes
Solution Approach 1:
The welding process is extracted and eliminated by replacing welded metal plates with an integrated connection plate structure. The connection plate is directly formed as part of the module housing through molding or extrusion processes, removing the need for separate welding operations and simplifying manufacturing.
Solution Approach 2:
The mechanical welding process is replaced with a structural integration approach. Instead of joining separate metal plates through welding, the connection plate is designed as an integral part of the housing structure, utilizing mechanical forming processes that are simpler and more cost-effective than welding operations.
4Volume of stationary object
If connection plates are designed with protruding and bending portions, then connection between adjacent modules is achieved without separate welding spaces, but the connection plate structure becomes more complex
Solution Approach 1:
The connection plate extends in multiple dimensions with protruding portions that reach adjacent modules and bending portions that facilitate connection. This multi-dimensional configuration allows the connection plate to perform electrical connection functions without requiring separate welding spaces, effectively utilizing the available volume in the front-rear direction.
Solution Approach 2:
The connection plate incorporates flexible bending portions that can adapt to slight misalignments between adjacent modules during assembly. This dynamic geometry allows the rigid-protruding portions to maintain electrical contact while the bending portions provide flexibility, simplifying the overall assembly process despite the complex shape.
Data Source
AI summary
A battery pack includes a plurality of battery modules arranged in a front and rear direction, and each of the plurality of battery modules includes a plurality of cylindrical battery cells; a module housing having a plurality of hollows in which the plurality of cylindrical battery cells are inserted and accommodated; and a connection plate having a body portion located at the upper portion or the lower portion of the plurality of cylindrical battery cells and provided with a plurality of connection terminals respectively in electrical contact and connection with the electrode terminal formed at one of the plurality of cylindrical battery cells, and a connection portion configured to protrusively extend in a left direction or a right direction from the body portion so that the protrusively extending portion is bent upward or downward from the body portion and the bent end is in contact and connection with a portion of another connection plate.