Integrated Substrate Battery Pack Vibration Stress Distribution
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Solution Overview
Problem
Conventional battery packs face challenges in manufacturing ease and vulnerability to vibration damage due to individual connection of electrodes with bus bars, leading to stress concentration and potential damage during vehicle operation.
Innovation Solution
A battery pack design featuring a substrate with integrated conducting paths that connects the battery modules, reducing connection complexity and stabilizing the modules during vibration by distributing stress evenly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bus bars are used to individually connect electrodes of adjacent battery modules, then electrical connection is achieved, but manufacturing complexity increases and stress concentration occurs during vibration
Solution Approach 1:
The patent merges multiple bus bars into a single integrated substrate that provides both mechanical support and electrical connection functions. The substrate integrates the connecting members and conducting paths into one unified component, eliminating the need for separate bus bars and reducing manufacturing complexity while maintaining connection reliability.
Solution Approach 2:
The substrate serves multiple functions simultaneously: it acts as a mechanical support structure, provides electrical connection through integrated conducting paths, and distributes vibration stress evenly across the battery modules. This multi-functionality replaces the single-purpose bus bars with a more versatile component.
2Reliability
If bus bars connect battery modules individually, then electrical connection is established, but vibration stress concentrates on bus bars and electrodes during vehicle operation
Solution Approach 1:
By merging multiple connection points into a single integrated substrate, the patent creates a unified structure that distributes vibration stress across the entire substrate area rather than concentrating it on individual bus bars and electrode connections.
Solution Approach 2:
The substrate acts as an intermediary between the battery modules, absorbing and distributing vibration stress before it reaches the electrode connections. This mediator function protects the vulnerable electrode-substrate interface from direct stress concentration.
3Stability of the object's composition
If multiple bus bars are used for module integration, then mechanical stability is improved, but manufacturing difficulty increases due to individual connections required
Solution Approach 1:
The patent combines multiple separate bus bar components into a single substrate, transforming a multi-step assembly process into a simpler single-step integration. The substrate is designed to connect to multiple battery modules simultaneously, dramatically simplifying the manufacturing process while maintaining mechanical stability.
Solution Approach 2:
The substrate is segmented into multiple connection regions that can independently connect to different battery modules, allowing modular assembly while maintaining overall structural integrity. This segmentation enables easier manufacturing compared to rigid single-point connections.
Data Source
AI summary
A battery pack includes a plurality of battery modules stacked with connecting terminals disposed at predetermined positions, a holding unit for holding the plurality of battery modules under the stacked state, a plurality of conducting paths connecting corresponding connecting terminals, and a substrate connected to the holding unit. The plurality of conducting paths are provided integrally in the substrate and disposed to connect the corresponding connecting terminals in association with connection of the substrate to the holding unit.