Battery Module Connection Laminate for Higher Volumetric Efficiency
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Solution Overview
Problem
Existing battery modules composed of laminated batteries suffer from poor volumetric efficiency due to the presence of two connection laminate layers between adjacent cells, which increases the overall module size and requires additional bus-bars for electrical connections.
Innovation Solution
A battery module design with a single connection laminate layer between unit cells, where the metal layer is electrically connected to the cathode and anode terminals of adjacent cells, reducing the need for bus-bars and optimizing the use of space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two connection laminate layers are used between adjacent battery cells, then electrical connection is achieved, but the module volume increases and volumetric efficiency decreases
Solution Approach 1:
The patent merges the functions of two separate connection laminate layers into a single integrated connection structure. The single connection laminate layer simultaneously connects the cathode terminal of one cell to the anode terminal of the adjacent cell, eliminating the need for two separate layers and reducing overall module volume while maintaining electrical connectivity.
Solution Approach 2:
The single connection laminate layer performs multiple functions: it serves as both the connection between cathode and anode terminals, and simultaneously acts as a structural support and insulating layer. This multi-functional design replaces what would traditionally require multiple separate components, reducing volume while maintaining all necessary functions.
2Reliability
If additional bus-bars are added for electrical connections, then electrical connectivity is ensured, but device complexity increases
Solution Approach 1:
The patent combines the functions of connection laminate layers and bus-bars into a single integrated structure. The metal foil within the connection laminate layer provides the electrical conduction function traditionally performed by separate bus-bars, while the resin layers provide insulation and structural support, eliminating the need for additional bus-bar components.
Solution Approach 2:
The patent extracts the electrical conduction function from the separate bus-bar component and integrates it directly into the connection laminate layer structure. The metal foil is embedded within the resin layers to form an integrated connection structure that performs both mechanical support and electrical conduction functions.
3Ease of manufacture
If traditional connection structures are used, then manufacturing is straightforward, but water permeation resistance is insufficient in high humidity environments
Solution Approach 1:
The patent uses a composite structure consisting of resin layers and metal foil layers. The resin layers provide water permeation resistance and insulation, while the metal foil provides electrical conduction. This composite material approach creates a multi-functional connection structure that resists water permeation while maintaining electrical connectivity and structural integrity.
Solution Approach 2:
The patent employs thin film structures where resin layers are laminated to form a protective barrier against water permeation. The flexible thin film structure of the connection laminate layer provides both mechanical flexibility for assembly and effective protection against moisture ingress in high humidity environments.
Data Source
AI summary
To provide a battery module with high volumetric efficiency. A battery module comprising stacked and connected unit cells each comprising a power generation element, a cathode terminal, and an anode terminal disposed on the opposite side of the cathode terminal of the power generation element, wherein a connection laminate layer including a resin layer, a metal layer and a resin layer in this sequence, is disposed between the unit cells, and wherein the metal layer of the connection laminate layer is electrically connected to the cathode terminal of one adjacent unit cell and the anode terminal of the other unit cell.