Cylindrical Cell Module Interconnects Without Wire Bonding
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Solution Overview
Problem
The existing cell module configurations face challenges in efficiently and cost-effectively connecting battery cells due to the complexity and variability of wire bonding, leading to increased costs and instability in fuse characteristics.
Innovation Solution
A cell module design featuring cylindrical cells with positive-electrode and negative-electrode terminals, where a connection intervening member with a tab and outward protrusion is mounted on the circumferential edge, electrically connected to the side surface, and conductive members with terminal connectors establish reliable connections, reducing manufacturing costs and improving stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire bonding is used to connect terminals and bus bars, then electrical connections can be established, but the bonding time increases, cost increases, and fuse characteristic stability decreases
Solution Approach 1:
The invention extracts the problematic wire bonding process from the connection system and replaces it with a direct mechanical and electrical connection structure. The terminal body with protrusions directly engages with recesses in the bus bar, eliminating the intermediate bonding wire and its associated complexity.
Solution Approach 2:
The terminal body acts as an intermediary component between the battery cell terminal and the bus bar. It provides a standardized interface with protrusions that mechanically and electrically connect to the bus bar recesses, simplifying the connection process while maintaining reliability.
2Reliability
If wire bonding is used to connect terminals and bus bars, then electrical connections can be established, but manufacturing cost increases
Solution Approach 1:
The terminal body is designed as a simple, inexpensive component that can be easily manufactured and replaced if needed. Its straightforward structure with protrusions makes it cheaper than complex wire bonding systems while maintaining adequate connection reliability.
Solution Approach 2:
The invention removes the expensive wire bonding process from the manufacturing system and replaces it with a simple mechanical connection structure that reduces manufacturing complexity and cost.
3Reliability
If wire bonding is used to connect terminals and bus bars, then electrical connections can be established, but fuse characteristic stability decreases due to variability in bonding wire dimensions
Solution Approach 1:
The terminal body provides a localized standardized connection interface with specific protrusion dimensions that ensure consistent electrical and mechanical connection properties. This local standardization eliminates the variability inherent in wire bonding processes.
Solution Approach 2:
The invention changes the connection parameter from variable wire bonding characteristics to fixed mechanical engagement dimensions. The protrusion and recess geometry provides consistent electrical contact pressure and connection reliability without the variability of manual or automated wire bonding.
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 design enables reliable and efficient electrical connections between cells, reducing manufacturing costs and enhancing the stability of the cell module by standardizing the bonding process and minimizing resistance.
Implementation Method 1
a tab extending along the side surface of the tube of each of the cells and electrically connected to the side surface
Data Source
AI summary
A cell module includes a plurality of cells that each have a cylindrical shape and include a positive-electrode terminal and a negative-electrode terminal disposed on one end of the cell. One of the terminals is located at a center, and the other terminal is located on a circumferential edge and is electrically connected to a side surface of a tube of each of the cells, a connection intervening member mounted on the other terminal includes a tab extending along the side surface of the tube and electrically connected to the side surface, and a hole that causes the center of the one end to be exposed. The plurality of cells make up a cell block where the one ends are oriented in an identical direction, and cells adjacent to each other are aligned in rows, on the one ends of the plurality of cells, a plate having electrical insulating properties is disposed, the plate is provided with a hole that causes the one end of each of the cells to be exposed and is further provided with a plurality of conductive members on a surface of the plate distant from the cells, the conductive members extend along the rows of the cells aligned, two of the conductive members are disposed for each cell block and include terminal connectors electrically connected to terminals, having identical polarity, of the cells in each cell block, and the other terminals are connected with the terminal connectors through the connection intervening member.