Secondary Battery Module Coupling via Electrode Terminal Through-Holes
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Solution Overview
Problem
Conventional secondary battery modules face challenges in achieving secure coupling and electrical connection between unit cells due to low mechanical strength of cell sheaths and lack of inherent coupling structures, leading to increased complexity and defects from external impacts.
Innovation Solution
Forming coupling through-holes with specific dimensions and shapes at electrode terminals of unit cells to allow for secure coupling and electrical connection without using cartridges, using coupling members inserted through these holes to align and connect the cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional pouch-shaped cells with plate-shaped electrode terminals are used, then the cells are light and inexpensive, but the mechanical strength of the cell sheath is lower and it is difficult to prepare a structurally strong battery module
Solution Approach 1:
The patent merges the electrode terminal with the coupling structure by forming through-holes directly in the plate-shaped electrode terminals. This integration eliminates the need for separate coupling members and simplifies the battery module assembly process while maintaining the lightweight and cost-effective advantages of pouch-shaped cells.
Solution Approach 2:
The patent performs preliminary action by pre-forming through-holes in the electrode terminals during cell manufacturing. This allows the electrode terminals to be ready for direct coupling when cells are stacked, eliminating the need for additional coupling components and simplifying the battery module assembly process.
2Strength
If additional coupling members are used to connect cells, then the mechanical strength is improved, but the device complexity increases
Solution Approach 1:
The patent combines the electrode terminal and coupling member into a single integrated structure. The through-holes formed in the plate-shaped electrode terminals allow direct insertion of connection elements, eliminating the need for separate coupling members and reducing structural complexity.
Solution Approach 2:
The plate-shaped electrode terminals serve dual functions: electrical connection and mechanical coupling. By forming through-holes in the electrode terminals, they can simultaneously conduct electricity and provide structural attachment points for connecting cells in the battery module.
3Volume of moving object
If cells are stacked one on another without cartridges, then the battery module size is reduced, but the electrical connection between cells becomes more difficult
Solution Approach 1:
The patent performs preliminary action by pre-forming through-holes in the electrode terminals during cell manufacturing. This allows for direct electrical and mechanical connection when cells are stacked, eliminating the need for cartridges and simplifying the assembly process.
Solution Approach 2:
The patent merges the electrical connection and mechanical coupling functions into a single integrated process. The through-holes in the electrode terminals allow connection elements to simultaneously establish electrical contact and provide mechanical support, eliminating the need for separate cartridge structures.
4Reliability
If the battery module is subjected to external impacts and vibrations, then the reliability is tested, but the electrical connection between components may become unstable
Solution Approach 1:
The patent performs preliminary action by pre-forming through-holes in the electrode terminals and designing the coupling structure to accommodate thermal expansion and contraction. This ensures stable electrical connection under external impacts and vibrations by maintaining proper contact pressure and alignment.
Solution Approach 2:
The patent incorporates design features that cushion against external impacts and vibrations. The coupling structure includes elements that can absorb mechanical stress and maintain electrical connection stability under varying environmental conditions, protecting against the harmful effects of external forces.
Data Source
AI summary
Disclosed herein is a process for preparation of a secondary battery module. The process includes forming coupling through-holes having specific shapes at plate-shaped electrode terminals of a plurality of unit cells, stacking the unit cells one on another, and inserting coupling members through the coupling through-holes to couple the unit cells with each other. Consequently, the secure coupling and the electrical connection between the unit cells is accomplished without using additional members, such as cartridges, and therefore, a compact battery module having high coupling force is prepared.