Pouch Cell Battery Module Layout for High-Density Vibration Resistance
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Solution Overview
Problem
Existing battery modules for vehicular use face challenges in maximizing energy density due to limited space, high vibration tolerance requirements, and the need to minimize non-functional volumes within the battery assembly.
Innovation Solution
The battery module design incorporates bent terminal tabs and a fastening portion made of electrically insulating material, which are strategically placed to minimize spare volumes and enhance structural rigidity, thereby maximizing energy density and vibration tolerance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional rigid connection structures (metal plates, frames) are used to connect battery terminals, then structural strength and connection reliability are improved, but device complexity and manufacturing difficulty increase due to multiple components and assembly steps
Solution Approach 1:
The patent combines the connection function and support function into a single integrated terminal structure. The terminal includes a support portion and a connection portion that are formed as one piece, eliminating the need for separate connection plates and reducing assembly steps while maintaining structural strength
Solution Approach 2:
The terminal structure serves multiple functions: it provides mechanical support for the battery element, establishes electrical connections between adjacent cells, and maintains spatial positioning. This multi-functional design reduces the number of components needed in the battery assembly
2Ease of operation
If terminal tabs are bent at right angles for connection, then connection ease and structural simplicity are improved, but space utilization deteriorates due to increased height and larger bounding box
Solution Approach 1:
The terminal connection structure transitions from a vertical bent-tab approach to a horizontal bridge-like connection that spans between adjacent battery elements. This dimensional change allows connections to be made at the same height level, reducing the overall height requirement and improving space utilization
3Reliability
If insulating materials are used to protect terminal connections, then electrical safety is improved, but energy density deteriorates due to increased non-functional volume
Solution Approach 1:
The insulating layer is integrated directly onto the terminal structure surface, forming a unified component. This eliminates the need for separate insulating housings or additional spacing, maintaining electrical safety while minimizing the volume occupied by non-functional materials
Data Source
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AI summary
The present invention discloses a battery module for various applications requiring a high energy density battery, or where the space for the battery is constrained. The battery module comprises one or more rows of battery cells (i.e. pouch cells). Terminal tabs (7, 8) of the cells can be folded 90 degrees on top of a fastening portion (1), before the terminal tab connections are made mutually and to the fastening portion (1) as well. Fastening portions (1) can be connected together from their ends, or replaced by longer elements reaching across several rows of cells. Internal metal layers (3) and compression pads (4) are used between the pouch cells, and the battery module is placed within a metal-made outer housing (11). The battery module is scalable in its size.