3D Connecting Member Layout for Compact Battery Cell Modules
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Solution Overview
Problem
Conventional cell modules have limited integration and conventional connecting members exhibit poor current-carrying capability, leading to potential thermal issues and stability problems due to narrow gaps between cell modules and direct contact with copper ribbons.
Innovation Solution
A connecting member design with a body portion and bending portions that change the length direction from horizontal to vertical and horizontal, allowing increased length and reduced gap size, incorporating buffer structures for stability and heat dissipation, and integrating with cell modules to enhance current-carrying capacity and reduce thermal risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If cell modules are arranged with small gaps to increase integration, then the degree of integration is improved, but the current-carrying capability of copper ribbons deteriorates and temperature rise occurs
Solution Approach 1:
The connecting member transitions from a planar copper ribbon layout to a three-dimensional structure with bending portions extending in multiple directions (first direction for body portion, second direction for bending portions, third direction for connecting portions). This spatial transformation allows the connecting member to achieve sufficient current-carrying length and cross-sectional area while adapting to compact cell module arrangements with small gaps, thereby resolving the contradiction between integration and current-carrying capability
Solution Approach 2:
The connecting member incorporates bending portions with specific angle ranges (0°-30° included angles, 0°-90° bending angles) that provide flexibility and adaptability. These dynamic geometric features allow the connecting member to accommodate variations in cell module spacing and maintain reliable electrical connection under different thermal and mechanical conditions, ensuring current-carrying capability while supporting high integration
2Reliability
If copper ribbons are used for electrical connection, then electrical connectivity is achieved, but temperature rise and stability problems occur due to direct contact with cell modules
Solution Approach 1:
The connecting member acts as an intermediary component between cell modules, replacing direct copper ribbon contact. Its extended body portion and connecting portions create a mediator structure that maintains electrical connectivity while providing thermal management benefits through increased surface area and improved heat dissipation pathways, thereby reducing temperature rise at connection points
3Reliability
If connecting members are extended in horizontal direction, then current-carrying capability is improved, but the gap between cell modules increases reducing integration
Solution Approach 1:
The connecting member utilizes three-dimensional space by extending the body portion in a first direction, adding bending portions in a second direction, and forming connecting portions in a third direction. This multi-directional spatial configuration allows the connecting member to achieve sufficient current-carrying dimensions without increasing the horizontal gap between cell modules, thereby maintaining high integration while ensuring reliable current transport
Data Source
AI summary
A connecting member is provided, including a body portion having first and second sides and extending from a first end to a second end of the body portion in a first direction, first and second bending portions, and first and second connecting portions. The first bending portion is bent from the first end towards a second direction on the first side, and the second bending portion is bent from the second end towards the second direction on the second side. The first connecting portion is bent from an end of the first bending portion away from the body portion towards a third direction that is from the second side to the first side. The second connecting portion is bent from an end of the second bending portion away from the body portion towards a fourth direction that is from the first side to the second side.