Insulating Plates Nipping Battery Electrode Tabs
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Solution Overview
Problem
Existing battery modules are susceptible to vibrations, leading to stress concentration on electrode tabs and reduced durability, and they lack compactness due to the need for maintaining distance between cells to prevent short circuits.
Innovation Solution
The battery module incorporates insulating plates that nip electrode tabs from both sides, providing electrical insulation and reducing the distance between cells, while also using spacers with heat sink layers to enhance heat dissipation and mechanical strength, allowing for closer cell stacking and improved vibration resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the distance between adjacent flat cells is decreased to compact the battery module volume, then the overall volume is reduced, but stress concentration on electrode tabs occurs under vibration leading to reduced durability
Solution Approach 1:
An insulating plate is introduced as an intermediary component between adjacent flat cells. This plate nipps the electrode tabs from both sides, providing mechanical support and stress distribution while maintaining electrical insulation. The insulating plate acts as a mediator that allows closer cell spacing without compromising electrode tab durability under vibration.
Solution Approach 2:
The insulating plate is constructed as a composite material structure combining an insulating base layer with a heat sink layer. This composite structure provides multiple functions: electrical insulation to prevent short circuits, mechanical strength for stress distribution, and thermal management capability. The composite nature allows the plate to withstand vibration stresses while maintaining reliability.
2Reliability
If insulating plates are introduced to protect electrode tabs, then vibration resistance is improved, but device complexity increases
Solution Approach 1:
The insulating plate is designed to perform multiple functions simultaneously: electrical insulation between cells, mechanical support for electrode tabs, stress distribution under vibration, and heat dissipation. By consolidating these functions into a single component, the overall device complexity is minimized while achieving reliable vibration resistance.
Solution Approach 2:
The insulating plate merges the functions of electrical insulation and mechanical support that would traditionally require separate components. The plate combines the insulating function with the structural support function, simplifying the battery module architecture while improving vibration resistance.
3Volume of moving object
If cells are stacked closer together, then compactness is achieved, but the risk of short circuits between electrode tabs increases
Solution Approach 1:
The insulating plate serves as a mediator between adjacent electrode tabs, maintaining electrical insulation even when cells are closely stacked. The plate's insulating properties prevent direct contact between electrode tabs from different cells, eliminating the short circuit risk while enabling compact cell arrangement.
Solution Approach 2:
The insulating plate provides localized electrical insulation precisely where needed - at the electrode tab interfaces between adjacent cells. This targeted insulation approach allows compact cell stacking without compromising safety, as insulation is applied only at the critical interfaces rather than throughout the entire cell structure.
Data Source
AI summary
A battery module has stacked therein a plurality of flat cells each formed by sealing a power generating element with a package member and deriving to the exterior electrode tabs from the package member and has the electrode tabs of the flat cells connected electrically. The battery module includes electrically insulated spacers adapted to nip the electrode tab from the opposite surface sides of the electrode tab along the stacking direction of the plurality of flat cells. The paired spacers nipping the electrode tab include an engaging member adapted to fasten the electrode tab by being passed through the electrode tab along the stacking direction.