Battery Module Cap Structure for Simplified Cell Connection
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Solution Overview
Problem
Conventional battery modules require cumbersome and time-consuming processes for electrically connecting multiple unit cells, especially in high-power applications like electric vehicles, due to the need for separate conductors and complex assembly methods such as welding or using nuts, which complicates maintenance and replacement of cells.
Innovation Solution
A cap structure with an attaching part and a circuit connection part that includes insertion grooves and conductive wires to facilitate easy electrical connection and disconnection of unit cells, allowing for series or parallel configuration without separate individual connections, and featuring a resin mold layer for protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate conductors with nuts or welding are used to connect unit cells, then reliable electrical connection is achieved, but assembly complexity and time increase significantly
Solution Approach 1:
The patent merges the conductor, connection terminal, and fastening structure into an integrated cap assembly. Each cap assembly contains conductors that electrically connect multiple unit cells and simultaneously provides the mechanical fastening function, eliminating the need for separate nuts and individual conductor connections for each cell pair.
Solution Approach 2:
The cap assembly serves multiple functions: it acts as an electrical conductor connecting cells in series or parallel, provides mechanical support and positioning for terminals, and functions as a fastening mechanism to secure the connection. This multi-functional design reduces the number of separate components needed.
2Reliability
If separate conductors with nuts are used to connect unit cells, then electrical connection is achieved, but maintenance and replacement time increase
Solution Approach 1:
The battery module is segmented into independent unit cells that can be individually accessed and replaced. The cap assemblies are designed to be removable, allowing a troublesome unit cell to be disconnected by simply removing its cap assembly without needing to access or manipulate other cells or their connection components.
3Reliability
If welding is used to fix conductors, then strong electrical connection is achieved, but cell replacement becomes difficult
Solution Approach 1:
The connection system transitions from a static welded joint to a dynamic, reversible mechanical connection. The cap assembly uses removable fasteners (such as bolts or clips) that allow the connection to be easily assembled and disassembled multiple times, providing the strength needed for operation while enabling simple maintenance and replacement.
Data Source
AI summary
A battery module combines a plurality of a unit cells mounted into a cap structure. The cap structure includes a circuit electrically connecting the unit cells.