Battery Module Assembly With Compensating Elements for Width Control
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Solution Overview
Problem
Existing battery module production methods fail to consistently achieve a defined overall width, especially when battery cells of different widths are used, leading to inefficiencies in interconnection and potential mechanical or chemical issues due to varying cell dimensions.
Innovation Solution
A method involving the recording of each battery cell's width under a defined force, followed by the strategic placement of compensating elements between adjacent cells to ensure a consistent overall width of the battery module, allowing for precise arrangement and interconnection of prismatic or pouch cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If battery cells of different widths are used to increase adaptability, then the battery module cannot achieve a defined overall width
Solution Approach 1:
A compensating element is introduced as an intermediary component between battery cells of different widths. This compensating element has a variable width that compensates for the width differences of adjacent battery cells, thereby maintaining a defined overall width of the battery module while accommodating cells with varying widths.
Solution Approach 2:
The width parameter of the compensating element is dynamically adjusted based on the width parameters of adjacent battery cells. By changing the width of the compensating element, the system adapts to different battery cell configurations while maintaining a constant overall module width.
2Manufacturing precision
If compensating elements are added to achieve defined width, then device complexity increases
Solution Approach 1:
The compensating element is applied locally only where width variations occur between battery cells, rather than uniformly across the entire module. This localized approach maintains manufacturing precision at critical interfaces while minimizing the overall increase in device complexity.
3Ease of manufacture
If battery cells are arranged adjacent to each other without compensation, then assembly is simple, but mechanical stability deteriorates
Solution Approach 1:
The compensating element serves as a mediator between adjacent battery cells, ensuring uniform contact and distribution of mechanical forces. This intermediary component enhances the mechanical stability of the battery module assembly while maintaining a relatively simple assembly process.
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 enables the production of battery modules with a consistent overall width, accommodating cells of varying widths, thereby enhancing mechanical stability and ensuring reliable electrical connections, while also compensating for potential air pockets or cavities within the cells.
Implementation Method 1
the width of a battery cell is recorded when a defined force is applied to the respective battery cell
Data Source
AI summary
A method for producing a battery module, having a plurality of prismatic battery cells and/or a plurality of battery cells in the form of pouch cells, includes in a first method step detecting a width of a battery cell when a defined force is applied to the respective battery cell. In a second method step, the plurality of battery cells are arranged adjacent to one another in a longitudinal direction of the battery module, and a compensating element is arranged between two battery cells arranged directly adjacent to one another. A width of the compensating element is formed in such a way that a sum of the widths of the two battery cells arranged directly adjacent to one another and the width of the compensating element has a defined value, so that ultimately the battery module has a defined overall width.