Battery Module Press-Fit Current Collector Assembly
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Solution Overview
Problem
Existing battery modules require complex and time-consuming manufacturing processes involving screwing, bonding, or welding to connect current collector structures with battery cells, which can compromise reliability and efficiency.
Innovation Solution
A battery module design utilizing press fit connections between negative and positive current collector structures and battery cell terminals, eliminating the need for screwing, bonding, or welding, and ensuring reliable mechanical and electrical connections through frictional forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screwing, bonding, or welding is used to connect current collector structures with battery cells, then reliable mechanical and electrical connections are achieved, but manufacturing complexity and time increase
Solution Approach 1:
The patent replaces complex mechanical connection systems (screws, bonding agents, welding equipment) with a simple press fit mechanical interference connection. The connection portion of the current collector structure is inserted into a receptacle on the battery cell terminal, creating a reliable connection through friction and geometric interference without requiring additional fastening mechanisms or thermal processes.
Solution Approach 2:
The press fit connection structure is designed to self-lock and self-align during insertion. The geometric interference between the connection portion and receptacle creates automatic positioning and securing, eliminating the need for separate fastening operations, alignment procedures, or quality control steps for additional connection elements.
2Reliability
If screwing, bonding, or welding is used to connect current collector structures with battery cells, then reliable mechanical and electrical connections are achieved, but manufacturing time increases
Solution Approach 1:
The patent replaces time-consuming mechanical connection systems (screws, bonding, welding) with a rapid press fit insertion process. The connection portion is simply inserted into the receptacle, creating an immediate secure connection without requiring threading, curing time, or thermal processing, thereby dramatically reducing cycle time per connection.
Solution Approach 2:
The current collector structure and battery cell terminals are pre-designed with matching press fit geometries during manufacturing. The connection portion and receptacle are precision-formed in advance, so that during assembly, no additional preparation, alignment, or adjustment is needed—only simple insertion is required to achieve a reliable connection.
3Productivity
If press fit connections are used to connect current collector structures with battery cells, then manufacturing complexity and time are reduced, but connection reliability may be compromised
Solution Approach 1:
The patent applies local quality by designing the connection portion and receptacle with specific geometric features optimized for press fit engagement. The receptacle may include tapered sections, ribs, or interference-fit geometries that concentrate mechanical engagement forces at critical locations, ensuring reliable connection despite the simplicity of the overall press fit mechanism.
Solution Approach 2:
The patent utilizes composite material properties by combining conductive materials (for electrical connection) with mechanically robust materials (for structural integrity) in the current collector structure and terminal components. This ensures that the press fit connection achieves both electrical conductivity and mechanical strength simultaneously.
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 press fit connections reduce manufacturing complexity and time, enhance reliability, and improve electrical conductivity while maintaining mechanical integrity, facilitating efficient assembly and mounting of battery modules and vehicles.
Implementation Method 1
ensuring reliable mechanical and electrical connections through frictional forces
Data Source
AI summary
A battery module includes a plurality of secondary battery cells and a negative current collector. Each of the secondary battery cells includes an electrode assembly including a positive electrode, a negative electrode, and a separator interposed between the positive electrode and the negative electrode, a case accommodating the electrode assembly, a positive terminal electrically connected to the positive electrode, and a negative terminal electrically connected to the negative electrode. The case of each of the plurality of secondary battery cells has a groove that is part of the negative terminal. The negative current collector includes a negative connection portion mechanically and electrically connected with a first one of the plurality of secondary battery cells by a first press fit connection in the groove of the case.