Resin Series-Coupling Component for Battery Pack
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Solution Overview
Problem
Existing series-coupling methods for cylindrical batteries in battery packs, such as using metal tabs or integrated dish components, face issues with deformation, external short circuits, and increased production costs due to the need for additional insulators and complex manufacturing processes.
Innovation Solution
A series-coupling component made of resin, featuring a circular plate-shaped bulkhead with a central hole and radial groove for the tab, which securely holds batteries in a coaxial configuration, preventing deformation and external short circuits while reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal tab is used to couple cylindrical batteries in series, then the batteries can be electrically connected, but the folded tab bends again due to external forces causing the battery pack outer shape to deform
Solution Approach 1:
A resin coupling component is introduced as an intermediary between the metal tab and the external environment. This coupling component includes a holding portion that secures the folded tab and prevents it from bending again, while a protruding portion maintains the battery pack's outer shape. The resin material acts as a mediator that protects the vulnerable tab structure from external forces.
Solution Approach 2:
The resin coupling component is designed to anticipate and counteract external forces before they can cause deformation. The protruding portion of the coupling component preemptively maintains the outer shape, while the holding portion pre-secures the tab in its folded state, cushioning against future bending forces.
2Reliability
If a metal tab is used to couple batteries, then electrical connection is achieved, but accurate mounting of the strip-shaped metal plate in the radial direction is required
Solution Approach 1:
The resin coupling component serves as a mediator that simplifies the mounting process. Instead of requiring precise radial alignment of the metal plate, the coupling component provides a standardized interface with a through-hole that guides the tab assembly, reducing the precision requirements for manual or automated mounting operations.
3Ease of manufacture
If an integrated dish component is used to couple batteries without a tab, then manufacturing is simplified, but additional insulators are required preventing external short circuits and increasing production costs
Solution Approach 1:
The invention merges multiple functions into a single resin coupling component: electrical insulation, mechanical coupling, tab holding, and outer shape maintenance. By combining these functions that were previously distributed across multiple components (dish component, separate insulators, tab, etc.), the total number of parts is reduced while maintaining all necessary functions.
Solution Approach 2:
The resin coupling component is designed as a multi-functional universal component that simultaneously provides electrical insulation, structural support, tab retention, and shape maintenance. This universal component replaces the need for separate specialized components for each function.
4Strength
If complex press processes are used to manufacture metal coupling components, then structural integrity is achieved, but production costs increase
Solution Approach 1:
The invention changes the material parameter from metal to resin, which fundamentally alters the manufacturing process. Instead of requiring complex press processes for metal forming, the resin can be manufactured using simpler molding techniques, reducing process complexity while maintaining sufficient mechanical strength for the application.
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A series-coupling component for a battery pack is constituted of an integrated molded article made of resin, and includes a circular plate-shaped bulkhead portion 51, a cylinder portion 52 taking the bulkhead portion as a top surface and opening downward, an upper end side of the unit battery 10d being inserted into the cylinder portion 52, and a wall surface portion 53 erected upwardly along a peripheral edge of the bulkhead portion to hold a lower end side of the unit battery 10u, the wall surface portion is separated by a cutout portion 57 from an upper end of a cylindrical side surface up to a top surface 55 of the bulkhead portion at a part of the cylindrical side surface that opens at the upper side taking the bulkhead portion as a bottom, the bulkhead portion has a hole 54 that communicates in an up and down direction at a center and a groove 56 that has a rectangular cross-section on a top surface and opens at peripheral edges of the hole and the bulkhead portion, a convex electrode terminal 11 of the unit battery is inserted into the hole 54, a tab 20 formed by folding a strip-shaped metal plate 120 is housed in the groove 56, and the cutout portion is formed in a region that opens the groove at the peripheral edge of the bulkhead portion.