Modular Cell Connection Unit for Battery Modules
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Solution Overview
Problem
Existing cell connection units for battery modules are limited in adaptability and require complex, costly manufacturing processes, making them inflexible for different battery module designs and difficult to automate.
Innovation Solution
A cell connection unit (CCU) comprising interconnected busbars and carrier rails, where busbars are connected to cell terminals and carrier rails provide reception regions for secure, insulated connections, forming a lightweight, modular system suitable for automated fabrication and easy adaptation to various battery module designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing cell connection units are used, then battery cells can be connected, but adaptability to different battery module designs is limited and manufacturing complexity increases
Solution Approach 1:
The cell connection unit is divided into modular components: carrier rails with reception regions for battery cells, and busbars for electrical connections. This segmentation allows independent optimization and flexible reconfiguration for different battery module designs, improving adaptability while simplifying manufacturing of each component.
Solution Approach 2:
The carrier rails are designed with universal reception regions that can accommodate different battery cell configurations through standardized connection interfaces. The busbars are configured to provide multiple connection patterns, enabling the same CCU structure to adapt to various battery module designs without increasing manufacturing complexity.
2Adaptability or versatility
If complex manufacturing processes are used to achieve flexible design, then adaptability improves, but production costs increase
Solution Approach 1:
By segmenting the CCU into standardized carrier rails and busbars, each component can be manufactured using simple, cost-effective processes. The modular nature allows these components to be produced in bulk and assembled flexibly for different designs, reducing both manufacturing complexity and cost while maintaining design adaptability.
Solution Approach 2:
The design allows parameter variations in the carrier rails and busbars (such as length, position of reception regions, connection patterns) without changing the fundamental structure or manufacturing process. This enables design flexibility through parameter adjustment rather than process complexity, keeping production costs low.
3Device complexity
If manual assembly methods are used, then complex structures can be assembled, but automation difficulty increases and productivity decreases
Solution Approach 1:
The segmented modular structure of carrier rails and busbars enables standardized assembly operations that can be easily automated. Each module has defined connection points and interfaces, allowing robotic systems to efficiently assemble different configurations without complex programming, thereby increasing productivity while maintaining the ability to handle complex battery module designs.
Data Source
AI summary
A cell connection unit (CCU) for connecting a plurality of aligned battery cells of a battery module and a battery module including the CCU, the CCU including a plurality of busbars, each busbar of the plurality of busbars being connected to cell terminals of at least two battery cells of the plurality of aligned battery cells; and a plurality of carrier rails, at least some carrier rails of the plurality of carrier rails being mechanically connected to at least three busbars of the plurality of busbars, wherein the at least some carrier rails of the plurality of carrier rails include a first reception region connected to at least one busbar of the at least three busbars of the plurality of busbars, and a separate second reception region connected to two busbars of the at least three busbars of the plurality of busbars and electrically insulating the two busbars from each other.