Wavy Sensing Board Structure for Battery Pack Swelling
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Solution Overview
Problem
Battery packs face challenges in managing the swelling of battery cells, which can lead to displacement and instability in connections, affecting the performance and reliability of the battery pack, especially in high-power applications like electric vehicles.
Innovation Solution
A battery pack design featuring a wavy sensing board that absorbs displacement through a mechanism of protrusions and holes, allowing the board to stretch and deform, maintaining stable connections between battery cells and terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid sensing board is used to maintain connection stability, then connection stability is improved, but the board cannot accommodate battery cell swelling displacement
Solution Approach 1:
The sensing board is designed with a wavy configuration that allows it to dynamically adapt its shape. When battery cells swell, the wavy board can deform and stretch along the first direction, converting the rigid connection structure into a dynamic one that accommodates displacement while maintaining electrical connectivity
Solution Approach 2:
The sensing board's physical state is changed from flat to wavy, altering its mechanical properties. The wavy configuration enables the board to absorb swelling displacement through elastic deformation, changing its length and shape parameters in response to battery cell expansion
2Adaptability or versatility
If the sensing board is made flexible to absorb displacement, then adaptability to swelling is improved, but connection stability may be compromised
Solution Approach 1:
The sensing board is designed with a wavy (curved) configuration instead of a straight flat shape. This curvature allows the board to absorb swelling displacement through elastic deformation of the waves, while the continuous material structure maintains stable electrical connections throughout the deformation process
3Ease of manufacture
If a fixed sensing board structure is used, then manufacturing simplicity is improved, but the structure cannot accommodate battery cell swelling
Solution Approach 1:
The sensing board transitions from a static flat structure to a dynamic wavy structure that can adapt its shape. This design maintains manufacturing feasibility through standard PCB bending techniques while enabling the board to accommodate battery cell swelling through controlled deformation
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 absorbs displacement caused by swelling battery cells, ensuring stable connections and improved reliability and performance of the battery pack, even in high-power applications.
Implementation Method 1
the sensing board may be stretched in the first direction to absorb the displacement
Data Source
AI summary
A battery pack includes: a plurality of battery cells; busbars respectively connected to the plurality of battery cells; a holder accommodating the busbars; a sensing board seated on the holder, connected to the busbars, and extending in a wavy manner in a first direction; and sensing terminals connecting the busbars to the sensing board and being configured to detect state information about the plurality of battery cells. The sensing board has holes in both sides thereof, and the holder includes protrusions respectively inserted into the holes. In response to the sensing terminals moving, the holes in the sensing board move with respect to the protrusions to stretch the sensing board.