Fingered Battery Cell Tab Terminal for Low-Force Busbar Bending
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Solution Overview
Problem
Existing tab terminal configurations for battery cells in electrified vehicles require high force for bending, which can damage the battery cell housing and compromise the reliability of electrical connections.
Innovation Solution
A tab terminal configuration with spaced-apart fingers that are bent to facilitate attachment to a busbar, reducing the force required for bending and ensuring secure electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional solid tab terminal is used for battery cell connection, then the electrical connection is simple and robust, but high force is required for bending which can damage the battery cell housing and compromise connection reliability
Solution Approach 1:
The tab terminal is segmented into multiple spaced-apart fingers instead of being a solid continuous structure. This segmentation allows each finger to bend independently with lower force requirements, reducing the overall bending force needed while maintaining electrical connection reliability through multiple contact points with the busbar
2Strength
If high force is applied to bend the tab terminal for secure attachment, then the connection security is improved, but the battery cell housing may be damaged
Solution Approach 1:
Dividing the tab terminal into multiple fingers distributes the bending stress across separate elements rather than concentrating it in a single solid structure. This reduces the peak force transmitted to the housing while achieving adequate connection strength through the collective attachment of multiple fingers to the busbar
Solution Approach 2:
The fingers are designed with specific local geometries and spacing that optimize the bending characteristics. The spaced-apart configuration allows each finger to deform locally with lower force requirements, preventing the transmission of excessive forces to the housing while maintaining adequate connection strength at the busbar interface
Data Source
AI summary
A battery pack may include a busbar including a slot. A battery pack may include a battery cell including a housing and a tab terminal extending from the housing in a first direction, wherein the tab terminal includes a plurality of fingers spaced-apart from one another in a second direction perpendicular to the first direction, and wherein each of the plurality of fingers is in direct contact with the busbar.