Battery Core Module Assembly for High-Density Pouch Cell Packs
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Solution Overview
Problem
Conventional pouch batteries have limited capacity due to single-dimensional stacking, complex assembly processes, and high costs associated with multiple parts, which hinder efficient and cost-effective battery core unit connections.
Innovation Solution
A battery core unit comprising multiple connected modules with brackets and conductive sheets, allowing for parallel connections of battery cores and efficient assembly, enabling high space utilization and easy replication for various battery sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery cores are connected by connection sheets and fastened by bolts, then the connection between battery cores is realized, but the assembly process becomes complicated and inefficient
Solution Approach 1:
The connection sheet and bolt are merged into an integrated connection structure where the connection sheet itself serves as both the electrical connector and the mechanical fastener. The connection sheet includes built-in clamping structures that directly clamp the battery core tabs without requiring separate bolts, thereby simplifying the assembly process while maintaining reliable electrical and mechanical connection.
Solution Approach 2:
The connection sheet is designed to perform multiple functions simultaneously: it provides electrical connection between battery cores, mechanical fastening through integrated clamping structures, and structural support. This multi-functional design eliminates the need for separate components like bolts and reduces assembly steps.
2Device complexity
If battery cores are stacked and fixed in a single dimension, then the battery structure is simple, but the overall battery capacity improvement is limited
Solution Approach 1:
The battery core arrangement transitions from single-dimensional stacking to multi-dimensional spatial configuration. Battery cores are arranged in both stacked layers and side-by-side configurations, utilizing three-dimensional space more effectively. This dimensional expansion allows more battery cores to be packed into the same volume, thereby increasing overall battery capacity while maintaining manageable structural complexity.
3Stability of the object's composition
If steel belts are used to bind battery cores after stacking, then the battery core assembly is secured, but the number of parts increases and costs rise
Solution Approach 1:
The binding function previously performed by separate steel belts is merged into the connection sheets and supporting pieces. These components are already required for electrical connection and structural support, so their binding function is integrated without adding separate parts. The connection sheets extend to bind adjacent battery core groups, while supporting pieces provide additional securing, thereby maintaining assembly stability while reducing the total number of parts.
4Reliability
If conventional assembly methods are used with multiple parts, then the connection is secure, but the assembly process is inefficient and costs are high
Solution Approach 1:
Multiple separate components (connection sheets, bolts, steel belts, supporting structures) are merged into integrated connection structures. The connection sheets incorporate both electrical connection and mechanical fastening functions, while supporting pieces combine structural support and binding functions. This reduction in component count directly improves assembly efficiency by reducing the number of assembly steps and fasteners required, while maintaining secure connections through the integrated multi-functional design.
Data Source
AI summary
A battery core includes battery core modules connected to each other. Each of the battery core modules includes at least one battery core group and brackets disposed at two ends of the at least one battery core group. Each of the at least one battery core group includes battery cores stacked along a first direction. Each of the brackets includes a bracket body and a conductive sheet mounted on the bracket body. The bracket body includes at least one tab protruding hole, and a tab of a battery core extends through the at least one tab protruding hole and is connected to the conductive sheet. Each of the battery core modules further includes a supporting and fastening piece disposed between the brackets at the two ends of the at least one battery core group.