Single-Layer Battery Module Interconnects for Easier Assembly
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Solution Overview
Problem
Conventional battery modules are difficult to manufacture due to complex procedures and require specialized machinery, necessitating a simpler and less expensive interconnect system.
Innovation Solution
A battery module with monolithic interconnect structures made of conductive metal, featuring positive and negative tabs connected to battery cells in a single layer, allowing for efficient series and parallel connections, thereby simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional battery interconnect systems are used, then reliable electrical connections are achieved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent combines multiple separate interconnect components into a single monolithic interconnect structure that integrates current collection, distribution, and cell connection functions into one piece, eliminating the need for multiple separate components and assembly steps
Solution Approach 2:
The monolithic interconnect structure performs multiple functions simultaneously: it collects current from multiple cells, distributes current to series/parallel connections, provides structural support, and enables both series and parallel connectivity configurations within a single component
2Manufacturing precision
If specialized machinery is used for battery module assembly, then precise interconnect placement is achieved, but manufacturing cost increases
Solution Approach 1:
The interconnect structure is pre-designed with predetermined connection points and geometries that automatically align with battery cell positions, eliminating the need for specialized placement machinery during assembly
Solution Approach 2:
The monolithic interconnect structure's geometry and connection points are designed to self-align with battery cells during assembly, allowing standard equipment to achieve precise placement without specialized machinery
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 easier and cost-effective manufacturing of battery modules by streamlining the interconnect system, improving the efficiency of electrical current flow and reducing production complexity.
Implementation Method 1
A plurality of monolithic interconnect structures is connected to the battery cells. The interconnect structures are formed from a conductive metal and include a plurality of tabs connected to the positive terminals of the battery cells and a plurality of negative tabs connected to the negative terminals of the battery cells.
Data Source
AI summary
A battery module having a plurality of battery cells arranged in groups. which are located in two or more module sections. A plurality of monolithic interconnect structures is connected to the battery cells. The interconnect structures are connected to the battery cells to have electrical current flow in a first direction in one of the module sections and flow in an opposing second direction in another one of the module sections. The interconnect structures are arranged in a single layer.