Battery Module Press Fit Current Collector Connection
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Solution Overview
Problem
Existing battery module connection methods for electric vehicles, such as screwing, welding, or bonding, are not suitable for circular cells due to their curved contact area, requiring precise positioning and increasing manufacturing complexity, and can lead to decreased electrical and mechanical connections over time due to thermal, chemical, and mechanical influences.
Innovation Solution
A battery module design utilizing press fit connections between the current collector structures and cells, where the negative and positive terminals have grooves and holes respectively, allowing for reliable mechanical and electrical connections without the need for screwing, bonding, or welding, using frictional and adhesive forces to maintain contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screwing, welding, or bonding methods are used to connect current collector structures to circular battery cells, then reliable electrical and mechanical connections can be achieved, but the manufacturing complexity increases due to precise positioning requirements and the need for specialized equipment
Solution Approach 1:
The patent replaces traditional mechanical connection methods (screws, welding, bonding) with a press-fit mechanical insertion system. The connection portion is inserted into a recess in the battery cell case, creating a reliable connection through friction and geometric interlocking rather than through complex joining processes. This substitution eliminates the need for specialized equipment and precise positioning while maintaining connection reliability.
2Reliability
If traditional connection methods are used for circular battery cells, then electrical connectivity can be established, but the manufacturing time and production efficiency decrease due to complex assembly procedures
Solution Approach 1:
The connection system is segmented into distinct components: a connection portion with connection element, a current collector structure, and a battery cell case with recess. This segmentation allows for independent manufacturing and assembly of each component, simplifying the overall manufacturing process and enabling parallel production, thereby improving productivity while maintaining connection stability.
Solution Approach 2:
The connection portion is pre-formed with the connection element and electrical conductor integrated into a single component before assembly. This preliminary action eliminates the need for on-site assembly operations such as screwing, welding, or bonding during battery module assembly, significantly reducing manufacturing time and improving production efficiency while ensuring consistent connection quality.
3Strength
If screwing, welding, or bonding methods are employed to connect battery components, then durable connections can be achieved, but the manufacturing cost increases due to additional equipment and process requirements
Solution Approach 1:
The patent replaces complex mechanical joining systems (screws, welding equipment, bonding processes) with a simple press-fit insertion mechanism. The connection portion is inserted into the recess and held in place by friction and geometric interlocking, creating a durable connection without requiring specialized equipment or complex processes. This significantly improves ease of manufacture while maintaining connection durability through proper design of the connection element and recess geometry.
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
This design simplifies the manufacturing process, reduces complexity and time, and provides reliable and efficient mechanical and electrical connections, enhancing the durability and efficiency of the battery module and electric vehicle.
Implementation Method 1
using frictional and adhesive forces to maintain contact
Implementation Method 2
using frictional and adhesive forces to maintain contact
Data Source
Figure 1~2
Figure 3~4
AI summary
The present disclosure refers to a battery module (12) for an electric vehicle (300), comprising: a plurality of secondary battery cells (20), at least one positive current collector structure (28), and at least one negative current collector structure (29a, 29b); wherein each of the secondary battery cells (20) comprises an electrode assembly including a positive electrode, a negative electrode, and a separator interposed between the positive electrode and the negative electrode, a positive terminal (25) electrically connected to the positive electrode, a negative terminal (23) electrically connected to the negative electrode, and a case (27) receiving the electrode assembly; wherein the at least one positive current collector structure (28) is arranged to interconnect the positive terminals (25) of at least two of the plurality of secondary battery cells (20) with each other, and the at least one negative current collector structure (29a, 29b) is arranged to interconnect the negative terminals (23) of at least two of the plurality of secondary battery cells (20) with each other; wherein the case (27) of each of the plurality of secondary battery cells (20) comprises a groove (30), and the groove (30) comprises at least a part of the negative terminal (23) of said secondary battery cell (20); wherein the at least one negative current collector structure (29a, 29b) comprises at least one negative connection portion (31a, 31b, 31c, 31d) projecting into the groove (30) of the case (27) of one of the plurality of secondary battery cells (20) to electrically connect the negative current collector structure (29a, 29b) and the negative terminal (23) of said secondary battery cell (20); and wherein the negative connection portion (31a, 31 b, 31c, 31d) and the groove (30) are mechanically connected with each other by a first press fit connection (37), and/or the positive terminal (25) of at least one of the plurality of secondary battery cells (20) comprises a hole (36a, 36b), wherein the at least one positive current collector structure (28) comprises at least one positive connection portion (32a, 32b) projecting into said hole (36a, 36b) to electrically connect the positive current collector structure (28) and the positive terminal (25) of said secondary battery cell (20), wherein the positive connection portion (32a, 32b) and the hole (36a, 36b) are mechanically connected with each other by a second press fit connection (38).