Battery Module Multilayer Wiring Board Current Collector Design
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Solution Overview
Problem
Conventional battery modules require numerous current collector members and insulation components on both axial sides of cylindrical batteries, leading to increased complexity, material costs, and potential welding defects, which complicates assembly and recycling.
Innovation Solution
A battery module design featuring a multilayer wiring board with elastically deformable positive electrode current collector members and ring-shaped negative electrode current collector members that engage with the battery case, eliminating the need for axial-side components and reducing the necessity for welding, thereby simplifying the structure and improving cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current collector members are individually welded to both end surfaces of each cylindrical battery, then electrical connection is achieved, but the number of components and welding operations increases significantly
Solution Approach 1:
The patent merges the functions of current collection and insulation by integrating the insulation member with the current collector member to form a single integrated component. This reduces the total number of parts from multiple separate components (current collector + insulation member) to one unified structure, thereby simplifying assembly and reducing component count while maintaining both electrical connection and insulation functions
Solution Approach 2:
The current collector member is designed to perform multiple functions simultaneously: it collects current from the battery terminals and provides electrical insulation where needed. The integrated structure serves dual purposes, eliminating the need for separate insulation components and reducing overall system complexity
2Reliability
If current collector members and insulation members are provided on both axial sides of each cylindrical battery, then electrical connection and insulation are ensured, but material costs and assembly complexity increase
Solution Approach 1:
The insulation function is merged into the current collector member structure itself. The integrated component includes insulation portions that extend to provide electrical isolation where required, eliminating the need for separate insulation members and simplifying the manufacturing process by reducing the number of assembly steps
3Reliability
If numerous welding operations are performed for mounting current collector members, then electrical connections are established, but productivity decreases and welding defects may occur
Solution Approach 1:
The patent extracts the welding operation from the assembly process by using a press-fit mechanism instead. The current collector member is designed with a insertion structure that mechanically engages with the battery terminal through pressing forces, eliminating the need for welding operations entirely and significantly improving assembly speed and productivity
4Reliability
If current collector members are welded to battery cases, then electrical connection is achieved, but recycling becomes more difficult
Solution Approach 1:
The welding process is completely removed from the connection mechanism. The press-fit design allows for easy disassembly by simply removing the pressing force, enabling the current collector member to be detached and reused or recycled without the need for welding removal processes, thereby improving recyclability
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 configuration enhances productivity, reduces material costs, simplifies the structure, and improves cooling performance by eliminating the need for axial-side components and minimizing welding-related issues, while facilitating easier recycling of cylindrical batteries.
Implementation Method 1
each of the first current collector members is a member that is elastically deformable in an axial direction of the cylindrical battery
Data Source
AI summary
A battery module includes a plurality of cylindrical batteries, a wiring board, a plurality of positive electrode-side current collector members, and a plurality of negative electrode-side current collector members. The wiring board is a wiring board having a multilayer structure in which wiring patterns are formed in a plurality of layers, and includes a positive electrode-side wiring pattern and a negative electrode-side wiring pattern. The respective wiring patterns are formed as different layers of the wiring board. Each positive electrode-side current collector member electrically connects a sealing body functioning as a positive electrode external terminal of each cylindrical battery and the positive electrode-side wiring pattern. Each negative electrode-side current collector member electrically connects a case body functioning as a negative electrode external terminal of each cylindrical battery and the negative electrode-side wiring pattern.