Bent Connection Plate Structure for Dense Cylindrical Battery Modules
Find Innovative SolutionsGenerate Solutions
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 results in a larger, less efficient design.
Innovation Solution
A battery pack design featuring connection plates with body portions mounted at the upper or lower portions of cylindrical battery cells, with connection portions extending laterally and bent upward or downward to contact adjacent plates, eliminating the need for separate connection space and allowing for a slimmer module housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a separate space for welding metal plates is provided in the module housing, then metal plates can be mounted and connected, but the battery module housing becomes larger and energy density deteriorates
Solution Approach 1:
The connection plate integrates both the mounting function (body portion) and the welding connection function (connection portion) into a single component. The body portion is mounted on the battery module housing while the connection portion extends to connect with adjacent modules, eliminating the need for separate welding spaces within the housing.
Solution Approach 2:
The connection portion extends in the horizontal direction from the body portion and bends upward or downward to contact adjacent connection plates. This spatial arrangement moves the welding connection interface outside the vertical housing space, allowing modules to be closely arranged in the front-rear direction without requiring internal welding clearance.
2Productivity
If battery modules are closely arranged in the front and rear direction, then more modules can be accommodated, but separate welding space must be provided which increases housing size
Solution Approach 1:
The connection portion extends horizontally and bends vertically to establish welding connections with adjacent modules. This three-dimensional configuration allows modules to be positioned immediately adjacent to each other in the front-rear direction, maximizing packing density without requiring additional longitudinal space for welding operations.
Solution Approach 2:
The connection plate's own structure provides the welding interface through its connection portion that naturally extends and positions itself for contact with adjacent modules. This self-positioning capability eliminates the need for dedicated welding chamfers or recesses in the housing structure.
3Reliability
If conventional metal plates are used for connection, then electrical connection is achieved, but welding heat can damage battery cells
Solution Approach 1:
The connection plate serves as an intermediary component between the battery module housing and adjacent modules. The body portion is mounted on the housing while the connection portion performs the welding operation, positioning the heat-generating welding process away from the battery cells and housing internal structures that could be damaged by excessive heat.
Data Source
Figure 1
Figure 2
Figure 3
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.