Battery Module Terminal Connection Member Design
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Solution Overview
Problem
High-power battery modules face challenges in efficiently and safely connecting multiple battery cells to maintain stable high current flow while ensuring insulation and safety, particularly in applications like electric vehicles where energy density and power requirements are high.
Innovation Solution
A terminal connection member with c-shaped sections and an elastic deformable design that connects battery cell terminal portions, providing a firm structure with flexibility to ensure efficient current flow and secure assembly, using materials like aluminum and copper, and employing welding for enhanced adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a terminal connection member connects multiple battery cells in series to achieve high power output, then the power and energy density are improved, but the reliability and safety of current flow are worsened due to connection instability and insulation issues
Solution Approach 1:
The terminal connection member is divided into multiple contact portions (first contact portion, second contact portion, third contact portion) that can independently connect to different terminal portions of battery cells. This segmentation allows each contact portion to be optimized for its specific connection point, improving overall connection reliability while maintaining high power output capability through series configuration
Solution Approach 2:
The patent introduces a support portion that extends in a direction substantially perpendicular to the facing portions, creating a three-dimensional structure. This dimensional extension provides mechanical support and maintains proper spacing between contact portions, ensuring stable current flow paths and improving connection reliability without compromising power density
2Object-affected harmful factors
If the facing portions of contact portions are spaced apart to contact respective terminal portions, then the insulation properties are improved, but the structural complexity and device complexity increase
Solution Approach 1:
Multiple contact portions and the support portion are merged into a single integrated terminal connection member. This unified structure provides both electrical connection functions and mechanical support functions, reducing the number of separate components needed while maintaining proper spacing for insulation between contact portions
Solution Approach 2:
The support portion serves multiple functions: it provides mechanical support for the contact portions, maintains the spacing between contact portions for insulation, and contributes to the overall structural integrity of the connection member. This multi-functionality reduces structural complexity despite the need for spaced-apart facing portions
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
The solution effectively enhances the insulation properties and safety of the battery module, allowing for efficient high current flow and improved assembly tolerance, thereby addressing the challenges of connecting multiple battery cells in high-power applications.
Implementation Method 1
a terminal connection member connecting the first and second terminal portions together, the terminal connection member including: a first contact portion, the first contact portion having a first facing portion contacting the first terminal portion, a second contact portion, the second contact portion having a second facing portion contacting the second terminal portion
Implementation Method 2
The terminal connection member may be elastically deformable in the first direction, the terminal connection member being configured to press the first and second facing portions against the first and second terminal portions, respectively
Implementation Method 3
The first and second facing portions may be welded to the first and second terminal portions, respectively
Data Source
AI summary
A battery module includes a first battery cell, a second battery cell, and a terminal connection member connecting the first and second terminal portions together, and including: a first contact portion, the first contact portion having a first facing portion contacting the first terminal portion, a second contact portion, the second contact portion having a second facing portion contacting the second terminal portion, the second facing portion being spaced apart from the first facing portion in a first direction, an outermost portion of the first contact portion being spaced apart in the first direction from an outermost portion of the second contact portion by a first distance, and a support portion, the support portion extending in the first direction between the first contact portion and the second contact portion, the support portion having an overall length in the first direction that is greater than the first distance.