Battery Cell Connection Structure for Re-Coupling Failed Frame Joints
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Solution Overview
Problem
Existing battery module connection methods, such as riveting, make it difficult to separate the connection member from the frame without completely disassembling the module, especially when the coupling process fails, leading to potential damage and discard of the module.
Innovation Solution
A battery cell connection structure with a coupling portion featuring multiple position indication portions that guide the coupling process, allowing for the connection member to be re-coupled to the frame by removing and replacing defective parts without disassembling the module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If riveting process is used to fasten connection member to frame, then fastening force is increased and processing time is reduced, but separation becomes difficult and module must be completely disassembled upon coupling failure
Solution Approach 1:
The coupling portion is divided into multiple separable coupling positions, allowing the connection member to be detached at specific locations without requiring complete module disassembly. This segmentation enables localized repair and replacement while maintaining the overall structural integrity of the battery module.
Solution Approach 2:
The coupling structure transitions from a fixed, permanent riveted connection to a dynamic, reconfigurable connection system. The multiple coupling positions allow the connection member to be adaptively coupled and decoupled at different locations based on operational needs or failure modes, providing flexibility while maintaining strong fastening when properly coupled.
2Productivity
If riveting process is used to fasten connection member to frame, then processing time is reduced, but complete disassembly is required upon coupling failure
Solution Approach 1:
By segmenting the coupling portion into multiple independent coupling positions, the system enables localized coupling and decoupling operations. This eliminates the need for complete module disassembly when coupling failures occur, significantly reducing the time loss associated with repair and replacement operations.
3Ease of manufacture
If separate tool is used between connection member and frame, then interference with riveting process occurs, but coupling position indication portions enable precise coupling without tool interference
Solution Approach 1:
The coupling position indication portions are pre-formed on the coupling portion during manufacturing, establishing precise coupling locations before assembly. This preliminary positioning feature guides the coupling process and eliminates the need for complex external tools or fixtures during assembly, reducing both tool interference and overall device complexity.
Data Source
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AI summary
Disclosed herein is a battery cell connection structure including a connection member configured to connect a plurality of battery cells loaded in a frame to the frame, wherein the connection member includes a connection portion configured to be connected to the plurality of battery cells loaded in the frame and a coupling portion extending from the connection portion, the coupling portion being configured to be coupled to the frame, and the coupling portion is provided with a plurality of coupling position indication portions arranged in a line in the direction in which the coupling portion extends, the plurality of coupling position indication portions being configured to indicate a coupling position of the coupling portion at which the coupling portion is coupled to the frame.