Laminated Battery Module Z-Arrangement Current Collector
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Lithium-ion battery packs for electric vehicles face challenges in energy density due to complex wiring and spot welding, leading to pseudo soldering, heat generation, and reduced effective energy use, which limits the vehicle's mileage and increases the volume occupied by electrode sheets.
Innovation Solution
A battery module design featuring a Z-shaped arrangement of battery cells connected by a combined current collector sheet with different materials for tabs and a separator with concave and convex patterns, along with a temperature sensor and buffer rings, to enhance energy density and heat dissipation while maintaining structural integrity and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If wires are used to connect current collector sheets for series connection, then battery cells can be connected in series, but the internal battery becomes complicated and messy, occupying too much space
Solution Approach 1:
The patent merges the series connection function into the current collector sheet structure itself. The current collector sheet is designed with multiple connection points and conductive pathways that enable both parallel and series connections of battery cells without requiring separate wiring harnesses. This integration eliminates the need for additional wires, reducing complexity and freeing up space within the battery pack.
2Ease of manufacture
If spot welding is used to connect wires to current collector sheet, then electrical connection is established, but the welding point becomes loose under vibration or shocking, resulting in pseudo soldering and desoldering
Solution Approach 1:
The patent combines the electrical connection function with the mechanical support function into a single integrated current collector sheet structure. The sheet provides both the conductive pathway and the structural framework for holding battery cells, eliminating the need for separate wire connections that would require welding. This integration removes the weak welding joint entirely, improving reliability under vibration and shock conditions.
3Adaptability or versatility
If multiple wires are added for sampling and connection, then battery monitoring and connection are enabled, but the internal battery becomes more complicated and occupies more space
Solution Approach 1:
The patent integrates multiple battery functions including power connection, sampling, and monitoring into the current collector sheet structure. The sheet incorporates dedicated conductive pathways and connection points for different functions, eliminating the need for separate wiring for each function. This multi-functional integration reduces structural complexity while maintaining full battery functionality.
4Ease of manufacture
If cylindrical battery cells are used with spot welding, then battery assembly is simplified, but the contact area between poles and connecting pieces is small, reducing current through capacity and increasing heat
Solution Approach 1:
The patent combines the electrical connection and mechanical support functions into the current collector sheet, which provides large surface area contact with battery cell terminals. The sheet structure enables extensive contact area between the current collector and battery poles, significantly improving current through capacity and reducing resistive heat generation compared to small contact area spot welding connections.
Data Source
AI summary
The present invention provides a battery module, comprising a battery cell and a current collector sheet, the battery cell is provided with a positive electrode tab and a negative electrode tab, the positive electrode tab and the negative electrode tab are located at the opposite ends of the battery cell, the adjacent battery cells form a Z-type arrangement through the current collector sheet by putting the tabs in series, the said positive electrode tab of the battery cell is an aluminum foil tab or a copper foil tab, the negative electrode tab is a copper foil tab or an aluminum foil tab, and the material of the positive electrode tab and that of the negative electrode tab are not the same, the said current collector sheet is a combined current collector sheet, the current collector sheet is combined by an aluminum sheet and a copper sheet.