Secondary Battery Module Grooved Side Members
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Solution Overview
Problem
Medium- or large-sized battery systems using pouch-shaped lithium-ion polymer secondary cells face challenges with low mechanical strength, large volume due to plate-like cartridges, poor electrical connections, and increased risk of electrical short-circuits from external forces.
Innovation Solution
A secondary battery module with a rectangular parallelepiped structure featuring grooved side members for high-density unit cell mounting, integrated connection members for stable electrical connections, and insulating partitions to prevent short-circuits, allowing for efficient heat dissipation and modular coupling without additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If pouch-shaped lithium-ion polymer secondary cells are used as unit cells, then the battery system can be manufactured with flexible cell selection, but the mechanical strength of the unit cells is low leading to poor electrical connection stability
Solution Approach 1:
The connection member integrates multiple functions: it provides mechanical support for electrical connections, structural support for mounting unit cells, and thermal conduction pathways. By merging these functions into a single integrated component rather than separate elements, the system achieves stable electrical connections while maintaining the flexibility to use pouch-shaped cells.
Solution Approach 2:
The connection member is constructed from composite material comprising aluminum and copper, combining the advantages of both metals: aluminum provides oxidation resistance and thermal conduction, while copper provides excellent electrical conductivity. This composite structure resolves the contradiction by providing both mechanical strength for reliable connections and electrical performance.
2Ease of manufacture
If plate-shaped cartridges are used to mount unit cells, then the unit cells can be electrically connected in series or parallel, but the cartridges occupy large area and increase total battery system volume
Solution Approach 1:
The connection member utilizes the third dimension (vertical height) by incorporating stepped structures with different height levels. Unit cells are mounted at different heights on the connection member, allowing electrical connections in series or parallel configurations without requiring large horizontal area. This vertical arrangement significantly reduces the footprint and total volume of the battery system.
Solution Approach 2:
The connection member structure allows unit cells to be nested or stacked in a compact arrangement. Multiple unit cells are mounted on different levels of the stepped connection member, creating a nested configuration that maximizes space utilization and minimizes the overall volume occupied by the battery system.
3Ease of manufacture
If large protruding areas of cathode and anode are used for electrical connection, then electrical connection can be established, but the risk of electrical short-circuits increases for engineers and users
Solution Approach 1:
The connection member extracts and concentrates the electrical connection function to specific localized contact points rather than requiring large protruding areas of cathode and anode. The electrical connections are established through defined contact interfaces between the connection member and unit cells, minimizing exposed conductive surfaces and reducing short-circuit risk while maintaining manufacturing ease.
4Temperature
If large distance between cartridges is maintained for heat dissipation, then heat generated from unit cells can be effectively dissipated, but the total volume of the battery system is increased
Solution Approach 1:
The connection member merges the thermal management function with its structural and electrical connection functions. The aluminum-copper composite material provides inherent thermal conduction pathways that efficiently dissipate heat from unit cells through the connection member structure itself, eliminating the need for additional spacing or separate thermal management components.
Solution Approach 2:
The connection member acts as an intermediary thermal conduction pathway between unit cells and the battery system housing. Heat generated from unit cells is conducted through the aluminum-copper connection member structure, which serves as a heat sink and thermal management intermediary, enabling effective heat dissipation without requiring large distances between components.
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
The solution enables a compact battery system with stable electrical connections, reduced risk of short-circuits during manufacturing and use, and effective heat dissipation, addressing the volume and safety issues of conventional systems.
Implementation Method 1
the heat dissipation effect is very high, and therefore, desired heat dissipation is accomplished
Data Source
AI summary
Disclosed herein is a secondary battery module constructed approximately in a rectangular parallelepiped structure. The battery module includes a pair of side members (right and left side members) having pluralities of grooves formed at the inside surfaces thereof such that the sides of unit cells are securely fitted in the grooves and at least one connection member integrally formed with the side members such that the side members are spaced apart from each other by the width of the unit cells while the grooves of the side members face each other. A medium- or large-sized battery system is manufactured using one or more secondary battery module. The secondary battery module allows a plurality of unit cells to be mounted in the battery module with high density. Consequently, the total size of the battery system can be considerably reduced, and the electrical connection between the electrodes is highly stable. Furthermore, a risk of an engineer or a user being exposed to the electrical short-circuits is minimized, and a risk of electrical short-circuits due to external forces is greatly reduced.