Rail Type Socket Battery Module With Fewer Conductors

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Solution Overview

Problem

Existing battery modules require numerous conductors and insulative frames to connect battery cells in series and parallel, leading to increased production costs and time.

Innovation Solution

A battery module utilizing a rail type socket to connect cylindrical battery cells in parallel and series, eliminating the need for conductors and insulative frames by using a nickel-based rail type socket and aluminum connection members.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional conductors and insulative frames are used to connect battery cells, then reliable electrical connection is achieved, but production cost and production time are increased

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidproduction time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent merges the insulative frame and conductor into a single integrated rail type socket structure. The socket body provides insulation while the rail portions provide electrical connection, eliminating the need for separate conductors and insulative frames. This integration reduces the number of components and assembly steps, thereby reducing production time while maintaining reliable electrical connection.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The rail type socket serves multiple functions simultaneously: it provides mechanical support for battery cells, electrical insulation between positive and negative terminals, and electrical connection through the rail portions. This multi-functionality replaces multiple separate components (insulative frame, conductors, and fixing mechanisms), reducing assembly complexity and production time.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If conventional conductors and insulative frames are used to connect battery cells, then reliable electrical connection is achieved, but material cost is increased

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmaterial cost

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent merges the insulative frame and conductor into a single integrated rail type socket structure. The socket body provides insulation while the rail portions provide electrical connection, eliminating the need for separate conductors and insulative frames. This integration reduces the number of materials required and simplifies the bill of materials, thereby reducing material cost while maintaining reliable electrical connection.

Inventive Principle:

Principle #5Merging (Combining)

3Strength

If fixing adhesive is used to fix conductors to insulative frame, then secure connection is achieved, but production time is increased due to hardening time

Engineering Contradiction:

Improveconnection strengthVSAvoidproduction time

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent extracts and eliminates the fixing adhesive from the assembly process. The rail type socket's integrated structure provides inherent mechanical retention and electrical connection without requiring adhesive bonding. This removes the hardening time requirement and associated production delays while maintaining secure connection through the structural design of the socket itself.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the chemical bonding mechanism (adhesive hardening) with a mechanical retention system. The rail type socket's geometry and structure provide inherent mechanical retention for battery cells and conductors, eliminating the need for chemical bonding and its associated hardening time, thereby reducing production time while maintaining connection strength.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If many conductors are used to connect battery cells in series and parallel, then complete electrical connectivity is achieved, but device complexity is increased

Engineering Contradiction:

Improveelectrical connectivityVSAvoidnumber of conductors

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges multiple conductor functions into a single rail type socket structure. The rail portions extend to connect with multiple battery cell terminals, providing both series and parallel connectivity through the integrated structure. This reduces the number of separate conductor components from multiple individual wires to a single multi-functional rail assembly, thereby reducing device complexity while maintaining complete electrical connectivity.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS12334594B2Battery module having rail type socket and battery pack including the same

Publication Date: 2025.06.17 LG ENERGY SOLUTION LTD

AI summary

A battery module includes a plurality of battery cell assemblies. Each of battery cell assemblies includes two or more cylindrical battery cells connected to each other in parallel, and the plurality of battery cell assemblies are connected to each other in series. Each battery cell assembly having the parallel connection structure is configured such that negative electrodes of the two or more cylindrical battery cells are electrically connected to each other via a rail type socket. The series connection between the battery cell assemblies includes an electrical connection between the rail type socket and positive electrodes of battery cells of an adjacent battery cell assembly via connection members.