Battery Cell Assembly Layout to Prevent Conductive Portion Cracking
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Solution Overview
Problem
The assembly process of battery cells is cumbersome, leading to low efficiency and a high risk of conductive portion cracking due to tension during transportation and assembly.
Innovation Solution
A method involving stacking cell assemblies in a perpendicular direction for electrical connection and housing insertion, with pre-connected gathering portions and support structures to maintain stability and reduce area occupancy, ensuring consistent assembly posture and minimizing tension on conductive portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cell assemblies are assembled in a traditional flat layout, then the assembly process is simple, but the assembly area is large and conductive portions are prone to tension and cracking
Solution Approach 1:
The patent transitions from a traditional flat two-dimensional assembly layout to a three-dimensional stacked configuration. Cell assemblies are arranged vertically in multiple layers within the housing body, with conductive portions extending upward from each layer. This dimensional change reduces the horizontal assembly area while maintaining reliable electrical connections and minimizing tension on conductive portions during assembly and transportation.
2Productivity
If multiple assembly operations are performed separately, then each operation can be optimized, but the overall assembly process becomes cumbersome and time-consuming
Solution Approach 1:
The patent combines multiple assembly operations into a single integrated process. The cell assemblies are pre-stacked in the desired configuration before housing insertion, and the housing body is designed to accommodate this stacked arrangement directly. This merging of stacking and housing insertion operations eliminates the need for separate repositioning steps, thereby improving assembly efficiency while maintaining process simplicity.
3Manufacturing precision
If cell assemblies are repositioned during assembly, then proper positioning can be achieved, but the risk of tension on conductive portions increases
Solution Approach 1:
The patent performs the stacking operation as a preliminary action before housing insertion. The cell assemblies are pre-stacked in the correct vertical configuration with conductive portions properly aligned and connected. This preliminary stacking ensures that when the housing is inserted, no repositioning is needed, thereby maintaining manufacturing precision while minimizing tension on conductive portions throughout the assembly process.
Data Source
AI summary
An assembly method and an assembly apparatus. The assembly method is used for assembling a battery unit; the battery unit comprises a housing and a plurality of battery cell assemblies connected in series and/or in parallel and accommodated in the housing; each battery cell assembly comprises an active substance coating part and a conductive part; the conductive part is located at one end of the battery cell assembly in the first direction and is used for electrically connecting the active substance coating part and an electrode post of the battery unit; the assembly method comprises the following steps: stacking the plurality of battery cell assemblies in a second direction, the second direction being perpendicular to the first direction; electrically connecting the conductive pats of the plurality of battery cell assemblies; and placing the plurality of battery cell assemblies into the housing.