Rotationally Symmetrical Battery Module Assembly for High Cell Counts
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Solution Overview
Problem
The assembly structure of battery modules becomes complicated and time-consuming as the number of battery cells increases, necessitating a simpler structure for improved assembly efficiency and reduced weight.
Innovation Solution
A battery module design comprising symmetrical sub-modules with integrated sensing capabilities, where each sub-module includes a cell stack, end and center covers, side covers, and a busbar assembly, allowing for rapid assembly and integration of multiple sub-modules into a high-capacitance module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of battery cells is increased to form a high-capacitance battery module, then the energy storage capacity is improved, but the assembly structure becomes complicated and assembly time increases
Solution Approach 1:
The battery module is divided into multiple sub-modules, each containing a stack of battery cells. This segmentation allows the large number of battery cells to be organized into manageable units with standardized structures, reducing overall assembly complexity while maintaining high capacitance
Solution Approach 2:
Each sub-module uses a standardized configuration including cell stacks, end covers, center covers, and side covers. These universal components can be repeatedly assembled to create different battery module capacities, simplifying the assembly process regardless of the total number of cells
2Quantity of substance
If the number of battery cells is increased to form a high-capacitance battery module, then the energy storage capacity is improved, but the assembly time increases
Solution Approach 1:
By dividing the battery module into pre-assembled sub-modules, the assembly process is broken down into smaller, parallelizable tasks. Multiple sub-modules can be prepared simultaneously and then quickly integrated, significantly reducing total assembly time for high-capacitance modules
Solution Approach 2:
Sub-modules are pre-assembled with their internal components (cell stacks, covers, busbars, sensing modules) before being integrated into the final battery module. This preliminary preparation of standardized units accelerates the overall assembly process
3Quantity of substance
If multiple sub-modules are assembled to form a high-capacitance battery module, then the energy storage capacity is improved, but the weight of the battery module increases
Solution Approach 1:
Multiple sub-modules are integrated into a unified battery module structure with shared upper and lower covers. This merging approach eliminates redundant cover components that would otherwise be present in separate modules, reducing overall weight while maintaining high capacitance
Data Source
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AI summary
A battery module includes a first sub-module and a second sub-module disposed in a first direction, the first sub-module and the second sub-module respectively including a plurality of battery cells stacked in a second direction, which is perpendicular to the first direction, and a lower cover coupled to the first sub-module and the second sub-module. The first sub-module and the second sub-module are disposed to be rotationally symmetrical to each other about a central axis, which is perpendicular to both the first direction and the second direction.