Battery Module Structure with Receptacle Bus Bar Connections
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Solution Overview
Problem
Battery modules require multiple unit cells for sufficient capacity and voltage, necessitating a stable and flexible electrical connection method that allows for efficient manufacturing, assembly, and durability, while accommodating various shapes and structures.
Innovation Solution
A battery module structure featuring unit cells with positive and negative cell taps, coupled with receptacles and bus bars for electrical connection, enabling stable and flexible arrangement of unit cells with easy assembly and disassembly, and the use of nonconductive coatings for safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple unit cells are connected to achieve sufficient capacity and voltage, then the battery module capacity and voltage are improved, but the complexity of electrical connection structure increases
Solution Approach 1:
The battery module is divided into multiple unit cells, each with its own receptacle and bus bar assembly. This segmentation allows independent connection of each cell while maintaining overall module functionality, resolving the complexity issue by creating modular, repeatable connection units rather than a monolithic complex structure
Solution Approach 2:
The receptacle structure serves multiple functions: it provides electrical connection points for bus bars, structural support for cell taps, and alignment features for assembly. This multi-functionality reduces the need for separate components, thereby reducing overall connection structure complexity while enabling multiple cell connections
2Reliability
If a stable electrical connection is ensured between unit cells, then the reliability of battery module is improved, but the manufacturing and assembling difficulty increases
Solution Approach 1:
The receptacles are pre-assembled with bus bars and positioning features before unit cell installation. This preliminary preparation ensures that when cells are connected, the electrical connection is already optimized for stability, while the pre-assembly reduces on-site manufacturing complexity and assembly difficulty
Solution Approach 2:
The receptacle acts as an intermediary component between the cell tap and the bus bar. It provides a standardized interface that ensures stable electrical connection while simplifying the manufacturing process, as the receptacle can be produced independently and then assembled with other components
3Adaptability or versatility
If the battery module structure is made flexible to accommodate various shapes and arrangements, then the adaptability is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The receptacle and bus bar assembly serves as a universal connection unit that can be configured in different arrangements (series, parallel, or combinations). This universal design provides manufacturing precision through standardized dimensions and features, while enabling adaptability to various module shapes and configurations
Solution Approach 2:
The connection structure allows for dynamic configuration of unit cells in different arrangements. The standardized receptacle design maintains manufacturing precision through consistent features, while the overall system can be dynamically adapted to different shapes and configurations based on application requirements
Data Source
AI summary
Disclosed is a battery module structure including unit cells having positive and negative cell taps at an edge each unit cell to induce electricity, a plurality of receptacles respectively coupled to cell taps of unit cells, and a plurality of bus bars electrically connecting receptacles. Advantageously, the present invention, ensures a stable connection between the unit cells, makes manufacturing and assembling easy, ensures high durability, allows for implementation of various shapes and structures of the battery modules, and freely determines the arrangement structure and the number of the unit cells in various ways.