Bent Lead Member for Series Battery Module Assembly
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Solution Overview
Problem
Conventional battery modules face challenges in meeting varying power demands due to limited output of single cells and the risk of accidental short circuits from exposed leads, with no protection against overcurrent, overcharge, or overdischarge conditions.
Innovation Solution
The use of partially bent lead members to connect adjacent cells in series, with insulating supports and fasteners to prevent short circuits and integrated safety devices like fuses or PTC devices to protect against overcurrent and overcharge, allowing for modular assembly and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If leads are welded to electrode terminals to connect cells in series, then electrical connection is achieved, but the leads become exposed and vulnerable to short circuits
Solution Approach 1:
The patent introduces an insulating support as an intermediary component between the leads and the external environment. This insulating support covers the exposed leads while allowing electrical connection to pass through, effectively mediating between the need for electrical connectivity and the need for protection against short circuits.
2Reliability
If conventional welding methods are used to connect leads, then electrical connection is established, but fabrication flexibility for various power demands is limited
Solution Approach 1:
The patent segments the battery module into modular units where cells can be connected in series using standardized lead members. This segmentation allows flexible configuration of battery modules to meet various power demands while maintaining reliable electrical connections through the modular design.
Solution Approach 2:
The patent enables dynamic reconfiguration of battery modules by using detachable lead members that can be easily connected and disconnected. This allows the same cell units to be arranged in different series configurations to meet varying power demands, providing fabrication flexibility without compromising connection reliability.
3Device complexity
If no protection devices are used, then device complexity is reduced, but protection against overcurrent, overcharge, and overdischarge is unavailable
Solution Approach 1:
The patent merges the protection function with the existing lead member structure by integrating safety devices directly into the lead members or insulating supports. This combination provides protection against overcurrent, overcharge, and overdischarge while minimizing additional structural complexity, as the protection components are integrated rather than added as separate external systems.
Data Source
AI summary
Disclosed are a lead member and a secondary battery module having the same. The lead member is at least partially bent to connect two adjacent cells and form a single series circuit through electrode terminals of the cells. It is possible to easily and rapidly fabricating a battery module comprising a predetermined number of cells to meet various power demands for industrial instrument or electric cars by connecting the cells in series using detachable lead members.