Battery Module Welding and Stacking Mechanism
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Solution Overview
Problem
Middle- or large-sized battery modules face challenges with low mechanical strength, increased size due to complex assembly processes, and potential for short circuits, especially in vehicles subjected to external forces, requiring a solution that enhances mechanical strength and simplifies assembly while minimizing weight and size.
Innovation Solution
A battery module comprising stacked unit cells with plate-shaped battery cells connected by welding, incorporating a sensing unit with a voltage sensing member and a compact structural design using a high-strength sheathing member, and a simplified assembly process that eliminates the need for multiple mechanical and electrical connection members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple mechanical coupling members and electrical connection members are used to assemble battery cells, then the structural stability and electrical connection are improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines mechanical coupling and electrical connection functions into a single integrated structure. The battery case itself serves as both the mechanical housing and the electrical connection component, eliminating the need for separate mechanical coupling members and electrical connection members. This merging reduces assembly complexity while maintaining structural stability and electrical connectivity.
Solution Approach 2:
The battery case is designed to perform multiple functions simultaneously: it provides mechanical protection, structural support, and electrical connection. By making the battery case multi-functional, the patent eliminates the need for additional dedicated mechanical and electrical components, thereby simplifying the overall assembly process.
2Reliability
If multiple mechanical coupling members and electrical connection members are used, then the electrical connection reliability is improved, but the manufacturing cost increases
Solution Approach 1:
The patent merges the electrical connection function into the battery case structure itself. The battery case includes conductive portions that directly provide electrical connection between cells, eliminating the need for separate electrical connection members. This reduces the number of components and assembly steps, thereby lowering manufacturing cost while maintaining electrical connection reliability.
3Strength
If a conventional assembly process with multiple components is used, then the structural strength is improved, but the battery module size increases
Solution Approach 1:
The patent integrates the mechanical coupling function into the battery case structure. The battery case itself provides the mechanical strength and structural integrity needed to hold cells together, eliminating the need for separate mechanical coupling members. This integration reduces the overall battery module size while maintaining the necessary mechanical strength.
4Weight of moving object
If the battery module is designed for high integration with small size, then the weight to capacity ratio is improved, but the mechanical strength decreases
Solution Approach 1:
The patent employs composite material structures in the battery case design. The battery case uses composite materials that provide high strength-to-weight ratio, enabling the module to maintain mechanical strength while minimizing weight. This allows high integration with small size while compensating for the reduced mechanical strength through material properties.
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 provides a compact, structurally stable battery module with enhanced mechanical strength, reduced risk of short circuits, and lower manufacturing costs, suitable for applications in vehicles with limited installation space and exposed to external forces.
Implementation Method 1
connecting electrode terminals of a pair of unit modules by welding
Implementation Method 2
mounting a sensing unit, including a sensing member, to the welding part
Implementation Method 3
bending the welding part such that the unit modules are stacked
Data Source
AI summary
Disclosed herein is a middle- or large-sized battery module comprising a plurality of stacked unit cells, each unit module including two or more plate-shaped battery cells electrically connected with each other, each battery cell having electrode terminals formed at opposite sides thereof. The battery module is manufactured by connecting electrode terminals of a pair of unit modules by welding, mounting a sensing unit, including a sensing member, to the welding part and bending the welding part such that the unit modules are stacked, and repeatedly performing the above processes until all the unit cells are stacked.