Cylindrical Battery Module Busbar Groove Assembly for Reliable Joining
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Solution Overview
Problem
Existing battery module connection methods for cylindrical cells, such as screwing, welding, or bonding, are inefficient and complex, especially for high-volume production, as they require precise positioning and can lead to decreased elasticity and connection reliability over time.
Innovation Solution
A battery module design featuring a flat negative busbar aligned with the circumference of cylindrical cells, which projects into grooves in the cell case to establish a mechanical and electrical connection, eliminating the need for screwing, welding, or bonding, and ensuring reliable connections through plastic deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screwing, welding, or bonding methods are used to connect current collector structures to cylindrical battery cells, then reliable electrical and mechanical connections can be achieved, but the manufacturing process becomes complex and time-consuming, especially for high-volume production
Solution Approach 1:
The invention extracts the connection function from complex processes (screwing, welding, bonding) and integrates it directly into the current collector structure through grooves that mechanically engage with the battery cell terminals. This eliminates the need for separate connection operations while maintaining reliable electrical and mechanical contact.
Solution Approach 2:
The current collector structure is segmented with grooves that create discrete engagement points with the battery cells. These grooves act as individual connection zones that can be independently formed and engaged, simplifying the overall connection process while ensuring reliable contact at each connection point.
2Ease of manufacture
If elastic claws are used to connect current collector structures to battery cells, then mechanical connection can be achieved, but the connection reliability decreases over time due to elastic element degradation
Solution Approach 1:
The invention replaces long-lasting but complex connection methods with a simpler groove-based system that uses the structural integrity of the current collector itself rather than separate fastening elements. The grooves are formed directly in the current collector and provide permanent mechanical engagement without relying on degradable elastic materials.
Solution Approach 2:
The connection function is merged into the current collector structure itself through the groove features. Rather than using separate elastic claws or fasteners, the current collector is designed with integrated grooves that simultaneously provide mechanical engagement and electrical contact, eliminating the need for separate connection components.
3Reliability
If precise positioning is required for screwing or welding connections, then connection reliability can be maintained, but the device complexity and manufacturing time increase
Solution Approach 1:
The grooves in the current collector structure are pre-formed at specific positions that correspond to the battery cell terminals. This preliminary positioning of the connection features eliminates the need for complex real-time positioning during assembly, as the grooves guide and locate the battery cells automatically during installation.
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
This design simplifies manufacturing, enhances connection reliability, and reduces electrical transition resistance, improving the mechanical and electrical integration of battery cells within the module and pack, while being cost-effective and space-efficient.
Implementation Method 1
ensuring reliable connections through plastic deformation
Data Source
Figure 1
Figure 2~3
AI summary
The present disclosure refers to a battery module (12) for an electric vehicle (300), comprising: a plurality of secondary battery cells (20), at least one positive current collector structure (28), and at least one negative current collector structure (29a, 29b); wherein each of the secondary battery cells (20) comprises an electrode assembly (41) including a positive electrode, a negative electrode, and a separator interposed between the positive electrode and the negative electrode, a positive terminal (25) electrically connected to the positive electrode, a negative terminal (23) electrically connected to the negative electrode, and a case (27) receiving the electrode assembly (41); wherein the at least one positive current collector structure (28) is arranged to interconnect the positive terminals (25) of at least two of the plurality of secondary battery cells (20) with each other, and the at least one negative current collector structure (29a, 29b) is arranged to interconnect the negative terminals (23) of at least two of the plurality of secondary battery cells (20) with each other; wherein the case (27) of each of the plurality of secondary battery cells (20) comprises a groove (30), wherein the groove (30) is arranged along a circumference of said case (27) and the groove (30) comprises at least a part of the negative terminal (23) of said secondary battery cell (20); and wherein the at least one negative current collector structure (29a, 29b) comprises at least one flat negative busbar (42a, 42b) arranged in a plane that is aligned with the circumference of the case (27) of each of at least two of the plurality of secondary battery cells (20), wherein the at least one flat negative busbar (42a, 42b) projects into the groove (30) of the case (27) of each of said at least two secondary battery cells (20) to connect the negative current collector structure (29a, 29b) and the negative terminals (23) of said at least two secondary battery cells (20) with each other.