Battery Module Contact Spring Integration for Uniform Load
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Solution Overview
Problem
Existing battery storage systems for electric vehicles face challenges in minimizing volumetric weight, achieving uniform thermal and electrical load, and ensuring safety, particularly in the event of mechanical damage or accidents.
Innovation Solution
A battery storage module design featuring a base plate with receiving areas for negative poles and a parallel plate with openings for positive poles, connected via contact springs that are laser-welded for uniform electrical and thermal loading, allowing for flexible configuration and easy detachment of individual cells in case of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If individual battery cells are connected using conventional nuts or contact springs, then the battery system can be assembled, but the thermal and electrical load distribution across cells becomes non-uniform
Solution Approach 1:
The patent merges the electrical contact function and mechanical retention function into a single integrated contact spring assembly. The contact spring serves dual purposes: providing electrical connection between cells and mechanically retaining cells in the battery module, eliminating the need for separate nuts or connectors. This integration ensures uniform contact pressure and electrical load distribution across all cells, preventing premature failure while simplifying the assembly structure.
2Reliability
If the battery system is designed with fixed structural connections, then mechanical stability is achieved, but individual cells cannot be quickly detached in case of damage
Solution Approach 1:
The contact spring provides a dynamic, elastic connection between battery cells rather than a rigid fixed connection. The spring mechanism allows for easy detachment by simply pulling the cell away, as the elastic force can be overcome with minimal effort. This dynamic connection maintains mechanical stability during normal operation while enabling rapid cell removal in case of damage, limiting chemical reactivity to affected cells only.
3Adaptability or versatility
If the battery module uses a standardized design for all applications, then manufacturing is simplified, but flexibility in configuring different numbers and arrangements of cells is limited
Solution Approach 1:
The battery module is segmented into independent, identical units where each cell is individually retained by its own contact spring on the base plate. This segmentation allows cells to be independently added, removed, or replaced without affecting the structural integrity or electrical connections of other cells. The standardized contact spring design can accommodate different cell types and arrangements, providing flexibility in configuring battery modules for various applications while maintaining consistent manufacturing processes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design achieves a high power-to-weight ratio, uniform cell loading, and enhanced safety by allowing individual cells to be quickly disconnected from the electrical network, preventing overheating and chemical reactivity, thus improving the safety and performance of battery storage systems.
Implementation Method 1
The contact spring is arranged on a side of the parallel plate facing away from the individual battery cells and is permanently and electrically connected to the parallel plate by means of a laser welding process
Data Source
Figure 1A~1B
Figure 2B~3C
Figure 4A~5B
AI summary
A battery storage module (10) is described, comprising a plurality of battery cells (1), each with a negative terminal and a positive terminal arranged on the opposite side of the negative terminal, a base plate (2), and a parallel plate (3). The base plate (2) has a plurality of receiving areas, each designed to receive a battery cell (1). Each battery cell (1) is arranged with its negative terminal in one of the receiving areas of the base plate (2). The parallel plate (3) is arranged on the battery cells (1) on a side facing away from the base plate (2) and is designed to connect the battery cells (1) at their positive terminals.