Modular Battery Module Assembly With Protruding Cell Terminals
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Solution Overview
Problem
Existing battery assembly methods in electric or hybrid vehicles are cumbersome, requiring specific cell designs for housing compatibility and electrical connections, making servicing difficult.
Innovation Solution
A method involving a cell tray with protruding cell terminals for easy electrical connections before casing attachment, using interference fits and weldable casings, and integrated busbars with flexible printed circuit boards for efficient cooling and monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cells are inserted into a housing with terminals located at one end for electrical connections, then electrical connections can be made, but the cells have to be designed in a particular way to be compatible with the housing and method of electrical connection, and it is difficult to service such batteries once assembled
Solution Approach 1:
The battery module is divided into multiple cell trays, each holding a specific number of cells (e.g., 16 cells per tray). This segmentation allows for modular assembly where cell trays can be independently manufactured and assembled into the housing, providing design flexibility while simplifying the overall assembly process.
Solution Approach 2:
The cell tray design serves multiple functions: it holds cells in a structured arrangement, provides pathways for coolant flow, and facilitates electrical connections through integrated busbars. This multi-functionality eliminates the need for separate components, reducing assembly complexity while maintaining design flexibility.
2Ease of manufacture
If cells are inserted into a housing with terminals located at one end for electrical connections, then electrical connections can be made, but the cells have to be designed in a particular way to be compatible with the housing and method of electrical connection
Solution Approach 1:
The battery module is divided into multiple cell trays, each holding a specific number of cells (e.g., 16 cells per tray). This segmentation allows for modular assembly where cell trays can be independently manufactured and assembled into the housing, providing design flexibility while simplifying the overall assembly process.
Solution Approach 2:
The cell tray design serves multiple functions: it holds cells in a structured arrangement, provides pathways for coolant flow, and facilitates electrical connections through integrated busbars. This multi-functionality eliminates the need for separate components, reducing assembly complexity while maintaining design flexibility.
3Strength
If a housing encloses the cells after electrical connections are made, then the battery structure is complete, but it is difficult to service such batteries once assembled
Solution Approach 1:
The battery module is divided into multiple cell trays, each holding a specific number of cells (e.g., 16 cells per tray). This segmentation allows for modular assembly where cell trays can be independently manufactured and assembled into the housing, providing design flexibility while simplifying the overall assembly process.
Solution Approach 2:
The cell trays are designed to be removable from the housing, transforming the otherwise static enclosed structure into a dynamic, serviceable system. This allows technicians to access and replace individual cell trays without disassembling the entire battery module, maintaining structural integrity while enabling easy maintenance.
4Power
If more cells are used to increase power output, then higher power can be provided, but the weight of the battery increases
Solution Approach 1:
The patent employs thin-walled cell trays and housing structures that provide necessary structural integrity while minimizing material usage. The cell trays are designed with optimized wall thicknesses that balance structural strength with weight reduction, allowing higher power output through additional cells without proportionally increasing overall battery weight.
Solution Approach 2:
The cell tray design serves multiple functions: it holds cells in a structured arrangement, provides pathways for coolant flow, and facilitates electrical connections through integrated busbars. This multi-functionality eliminates the need for separate components, reducing overall weight while accommodating higher power output through efficient space utilization.
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
Facilitates easier assembly, enhances serviceability, improves power-to-weight ratio through efficient cooling, and allows for higher power output with fewer cells.
Implementation Method 1
inserting cells into respective cell holes until an interference fit is achieved between the cell tray surrounding the cell hole and the cell inserted into the respective cell hole
Implementation Method 2
Attaching the first casing may comprise welding the first casing to the cell tray. Attaching the second casing may comprise welding the second casing to the cell tray
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A method for assembling a battery module, the method comprising: providing a cell tray defining a plurality of cell holes for holding cells; inserting cells into respective cell holes so that the cells each protrude from the cell tray at each end of the cell; attaching a first casing to a first side of the cell tray to enclose the cell ends protruding from the first side; and attaching a second casing to a second side of the cell tray to enclose the cell ends protruding from the second side.