Battery Module Assembly With Protruding Cells and Split Casings
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Solution Overview
Problem
The existing methods for assembling battery modules are inefficient, requiring specific cell designs for housing and electrical connections, making it difficult to optimize power-to-weight ratio and service the batteries once assembled.
Innovation Solution
A method involving a cell tray with holes for holding cells, where cells protrude from both ends, allowing for the attachment of casings and electrical connections before encasing, using busbars and flexible printed circuit boards for efficient electrical connections and cooling, and securing cells with interference fit or resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cells are inserted into a housing with terminals located at one end for electrical connections, then electrical connections can be made, but the cells have to be designed in a particular way to be compatible with the housing and method of electrical connection, reducing adaptability
Solution Approach 1:
Instead of inserting cells into a housing and making electrical connections from one end, the patent inverts the sequence by first making electrical connections between protruding cell ends, then enclosing them with casings. This allows cells to be inserted into a cell tray first, with terminals protruding from both ends, enabling flexible cell designs without compatibility constraints.
2Reliability
If cells are enclosed in a housing with covers after electrical connections are made, then the battery is protected, but it becomes difficult to service the batteries once assembled
Solution Approach 1:
The patent divides the battery assembly into separable segments: a cell tray holding individual cells, first and second casings that enclose protruding cell ends. This segmentation allows the battery to be disassembled by removing casings to access and service cells, while still providing protection when assembled. The modular structure enables easy maintenance without compromising reliability.
3Productivity
If traditional battery assembly methods are used, then electrical connections can be made, but the assembly process is inefficient and power-to-weight ratio cannot be optimized
Solution Approach 1:
The patent performs preliminary actions by inserting cells into a cell tray structure first, establishing their positions and orientations before making electrical connections. The cell tray pre-defines the arrangement of cells, allowing for optimized power-to-weight ratio designs. This preliminary structuring enables more efficient assembly processes compared to traditional methods where cells are placed into housings and then connected.
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 method enhances the power-to-weight ratio by allowing for optimized cell arrangement and efficient cooling, improving the assembly process and serviceability of battery modules.
Implementation Method 1
inserting cells into respective cell holes until an interference fit is achieved between the cell tray surrounding the cell hole and the cell inserted into the respective cell hole
Implementation Method 2
attaching a first casing to a first side of the cell tray to enclose the cell ends protruding from the first side; and attaching a second casing to a second side of the cell tray to enclose the cell ends protruding from the second side
Data Source
AI summary
A method for assembling a battery module, the method comprising: providing a cell tray defining a plurality of cell holes for holding cells; inserting cells into respective cell holes so that the cells each protrude from the cell tray at each end of the cell; attaching a first casing to a first side of the cell tray to enclose the cell ends protruding from the first side; and attaching a second casing to a second side of the cell tray to enclose the cell ends protruding from the second side.