Pouch Cell Unit Assembly with Planar Carrier for Modular EV Batteries
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Solution Overview
Problem
Existing electrochemical cell units and energy storage modules in vehicles face challenges in terms of mass production efficiency, modular adaptability, and production costs, particularly due to the use of lead accumulators with high weight and low energy density, and the need for improved assembly methods.
Innovation Solution
The design incorporates lithium-ion pouch cells with planar elements and terminal lugs in a cell carrier, allowing for a compact, modular construction with flexible wiring options, and uses a shunt with flexible busbar connectors and a comb-shaped contacting device for efficient assembly, including laser or ultrasound weld seams for connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lead accumulators are used as starter batteries, then the vehicle starting function is reliable, but the weight increases significantly due to low energy density
Solution Approach 1:
The patent changes the chemical composition parameters of the battery by using lithium-ion chemistry instead of lead-acid chemistry. This fundamental parameter change enables achieving the same starting function with significantly reduced weight while maintaining or improving reliability through higher energy density and longer service life characteristics of lithium-ion technology
Solution Approach 2:
The patent employs composite construction by combining lithium-ion pouch cells with a planar element structure and cell carrier system. This composite approach integrates multiple functional elements (energy storage cells, structural support, thermal management interfaces) into a unified lightweight assembly that maintains reliability while reducing overall weight
2Adaptability or versatility
If conventional battery modules are designed, then the structure is simple, but the adaptability to various energy requirements is limited
Solution Approach 1:
The patent divides the battery system into modular cell units, each comprising pouch cells arranged around a central planar element. These standardized modules can be configured in series or parallel connections to achieve different voltage and capacity requirements, enabling adaptability without requiring fundamentally different designs for each application
Solution Approach 2:
The planar element structure serves multiple functions simultaneously: it provides structural support for the pouch cells, acts as a thermal management interface, enables electrical connections, and facilitates modular assembly. This multi-functionality allows the same basic module design to be adapted to various energy requirements through simple scaling and configuration changes
3Productivity
If manual assembly methods are used for battery modules, then the assembly process is flexible, but the production time and costs increase
Solution Approach 1:
The patent designs the cell carrier and planar element structures with pre-defined positioning features, connection points, and alignment elements. These preliminary structural preparations enable automated assembly equipment to quickly and accurately position and secure pouch cells without requiring complex manual dexterity or multiple adjustment steps, thereby increasing productivity while maintaining ease of manufacture
Solution Approach 2:
The patent replaces manual mechanical assembly operations with automated welding processes for creating electrical connections between terminal lugs and busbars. This substitution of manual mechanical work with automated welding systems dramatically increases assembly speed and consistency while reducing labor requirements and production costs
4Manufacturing precision
If non-planar cell arrangements are used, then the wiring flexibility is higher, but the manufacturing precision and automated production capability decrease
Solution Approach 1:
The patent employs asymmetric positioning of terminal lugs on pouch cells, with specific orientation relative to the planar element. This asymmetric but standardized arrangement provides sufficient wiring flexibility for different connection configurations while maintaining precise, repeatable positions that are easily accommodated by automated manufacturing equipment through fixed tooling and positioning fixtures
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 approach enables a compact, cost-effective, and reliable assembly process with reduced production time and costs, allowing for adaptable energy storage modules that can be easily scaled and integrated into vehicles.
Implementation Method 1
laser or ultrasound weld seams for connections
Implementation Method 2
laser or ultrasound weld seams for connections
Data Source
AI summary
The invention relates to an electrochemical cell unit for storing electrical energy, in which the electrochemical cell unit includes at least two lithium-ion pouch cells, a planar element for orienting the at least two lithium-ion pouch cells, and a cell carrier. The at least two lithium-ion pouch cells are provided in the cell carrier and are in electrical contact. The at least two lithium-ion pouch cells also have a first and a second terminal lug. The planar element is provided, preferably centrally, in the cell carrier and in addition, is sandwiched between the at least two lithium-ion pouch cells, at least some portions of the planar element being in contact with the pouch cells.