Battery Cell Terminal Configuration for EV Pack Assembly
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Solution Overview
Problem
The assembly of battery cells in electric vehicle battery packs is challenging due to the placement of positive and negative terminals, which requires complex wire bonding and welding, and the conductive casing can interfere with thermal management and insulation.
Innovation Solution
The battery cell design features both positive and negative terminals on the same lateral end, with conductive discs and an insulative material in between, allowing for easier wire bonding and potentially using non-conductive materials for the casing to enhance thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If positive and negative terminals are placed at opposite ends of the battery cell, then electrical isolation between terminals is improved, but wire bonding complexity and assembly time increase
Solution Approach 1:
The patent merges both positive and negative terminals into a single head region of the battery cell, allowing them to coexist in close proximity. This is achieved through the use of an insulating grommet that electrically isolates the terminals while enabling them to be positioned at the same end of the cell, thereby simplifying wire bonding and reducing assembly time without compromising electrical isolation
2Reliability
If conductive casing material is used for the battery cell housing, then electrical conductivity is improved, but thermal management effectiveness deteriorates
Solution Approach 1:
The patent employs composite material construction for the battery cell, specifically using an insulating grommet made of electrically insulating material (such as plastic or polymer) that also provides thermal management benefits. This composite approach allows the cell to achieve both electrical isolation and improved thermal characteristics, resolving the contradiction between electrical conductivity and thermal management effectiveness
3Reliability
If complex wire bonding and welding procedures are used for terminal connections, then connection reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-positioning the insulating grommet within the head region before final assembly. This pre-positioning ensures that the grommet is already in place to provide electrical isolation and guide wire routing, thereby simplifying the subsequent wire bonding and welding procedures while maintaining connection reliability, and reducing overall manufacturing complexity
Data Source
AI summary
Provided herein are battery cells for battery packs in electric vehicles. A battery cell can include a housing. The housing can have a body region, a neck region, and a head region. The body region can include an electrolyte, anode, and cathode. The battery cell can include a sealing element disposed in the head region. The battery cell can include two conductive layers and an insulation layer disposed within the sealing element. The first conductive layer can include a positive terminal to couple with a first wire connected to the cathode. The first conductive layer can define a first opening to pass a second wire. The second conductive layer can include a negative terminal to couple with the second wire connected to the anode. The second conductive layer can define a second opening to pass the first wire. The insulation layer can be disposed between the two conductive layers.