Movable Busbar Assembly for Battery Pack Swelling Relief
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Solution Overview
Problem
Existing battery packs face issues with short circuits and potential explosions due to swelling of unit cells, leading to damage of tabs and leads, and fixed busbar structures fail to provide sufficient movement distance during swelling, affecting performance and safety.
Innovation Solution
A battery pack design with movable busbar frames and busbars that allow for independent movement towards the side plates, incorporating elastic and corrugated connection busbars to accommodate swelling, reducing stress on leads and preventing short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If fixed busbar structures are used to connect battery cells, then structural stability is improved, but short circuits and lead damage occur during battery swelling
Solution Approach 1:
The busbar assembly is designed with movable components that can dynamically adjust their position during battery swelling. The busbar frame includes sliding structures that allow the busbar to move along the side plates, and the connection between busbar and battery cell tabs uses flexible connectors that can deform to accommodate volume changes, transforming the fixed structure into a dynamic one that adapts to swelling conditions
Solution Approach 2:
The connection between the busbar and battery cell tabs employs flexible connector structures that can deform elastically. These flexible connections allow the busbar assembly to accommodate the volume expansion of battery cells during swelling while maintaining electrical connectivity, preventing the rigid connection from causing lead damage or short circuits
2Ease of manufacture
If fixed busbar frames are used to support busbars, then manufacturing simplicity is improved, but insufficient movement distance is provided during swelling
Solution Approach 1:
The busbar frame incorporates sliding mechanisms that enable controlled movement along the side plates of the battery pack. This dynamic structure provides sufficient movement distance to accommodate battery swelling while maintaining a relatively simple manufacturing process through the use of guide rails and sliding interfaces
Solution Approach 2:
The busbar frame is divided into movable and fixed segments, with the busbar itself being movable relative to the busbar frame. This segmentation allows the busbar to move independently to accommodate swelling while the busbar frame provides structural support, balancing manufacturing simplicity with adaptability
3Strength
If busbars are fixed to side plates, then structural support is improved, but stress concentration damages leads and connections
Solution Approach 1:
The connection between busbars and battery cell tabs uses flexible connector structures that can deform elastically under stress. These flexible connections distribute the stress generated during battery swelling across a larger area and through deformation, preventing stress concentration that would damage rigid leads and connections
Solution Approach 2:
Flexible connector structures serve as intermediaries between the rigid busbar assembly and the battery cell tabs. These intermediaries absorb and distribute mechanical stress, protecting the leads and焊接 connections from damage while maintaining electrical connectivity during battery volume changes
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design effectively prevents damage to tabs and leads, maintains battery performance, and enhances safety by allowing for movement of busbars and frames, reducing the risk of short circuits and explosions.
Implementation Method 1
incorporating elastic and corrugated connection busbars to accommodate swelling
Data Source
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AI summary
Disclosed are a battery pack having a movable busbar assembly and a secondary battery including the same, and more particularly a battery pack having a movable busbar assembly configured such that at least one of a first busbar frame located at the front surface of a pack case, a second busbar frame located at the rear surface of the pack case, a first busbar connected to the first busbar frame, and a second busbar connected to the second busbar frame is movable in a direction toward a side plate of the pack case, whereby it is possible to minimize short circuit between leads, and a secondary battery including the same.