Rail Socket Battery Module Assembly With Fewer Connection Parts
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Solution Overview
Problem
Existing battery module manufacturing processes require multiple materials and lengthy production times due to the use of conductors, insulative frames, and fixing adhesives, leading to increased costs and inefficiencies.
Innovation Solution
A battery module design utilizing a rail type socket that connects cylindrical battery cells in series and parallel configurations, minimizing material usage and assembly time by employing a rail type socket with through-holes, side parts, and connection members to directly connect battery cells without the need for insulators or adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional conductors, insulative frames, and fixing adhesives are used to connect battery cells, then reliable electrical connection and insulation are achieved, but material cost and production time increase
Solution Approach 1:
The rail type socket merges the functions of electrical connection and mechanical support into a single integrated component. The socket directly contacts the terminals of multiple battery cells to establish electrical connections while simultaneously providing structural support, eliminating the need for separate conductors, insulative frames, and fixing adhesives used in conventional designs.
Solution Approach 2:
The rail type socket serves multiple functions simultaneously: it acts as an electrical conductor to connect battery cells in series and parallel configurations, provides mechanical support and positioning for the cells, and eliminates the need for separate insulative components. This multi-functionality reduces both material complexity and assembly steps.
2Ease of manufacture
If multiple materials (conductors, insulative frames, adhesives) are used for battery cell connection, then functional requirements are met, but material cost increases
Solution Approach 1:
The rail type socket combines multiple materials and components into a single integrated structure. Instead of using separate conductors, insulative frames, and adhesives, the socket is designed with conductive portions for electrical connection and structurally integrated features for support and positioning, thereby reducing material quantity and cost.
Solution Approach 2:
The rail type socket can be manufactured as a composite structure with conductive portions and insulative portions integrated into a single component. This allows the socket to provide both electrical connection and insulation functions while reducing the total material quantity compared to using separate components.
3Reliability
If conventional connection methods with multiple components are used, then reliable battery cell assembly is achieved, but production time and complexity increase
Solution Approach 1:
The rail type socket merges multiple assembly functions into a single component installation step. By integrating electrical connection and mechanical support functions, the socket reduces the number of assembly steps and components, thereby reducing assembly complexity while maintaining reliability through direct contact and stable positioning.
Solution Approach 2:
The rail type socket is designed with segmented functional portions: conductive portions for electrical connection and side parts with recessed portions for mechanical support. This segmentation of functions within a single component allows for simplified assembly while maintaining the reliability of each individual function.
Data Source
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AI summary
Disclosed are a battery module having a rail type socket and a battery pack including the same, and more specifically a battery module including a plurality of first battery cell assemblies, each of which is constituted by connecting two or more cylindrical battery cells (100) to each other in parallel, the plurality of first battery cell assemblies being connected to each other in series, wherein each first battery cell assembly having the parallel connection structure is configured such that negative electrodes of the two or more cylindrical battery cells (100) are electrically connected to each other via a rail type socket (200), and the series connection between the first battery cell assemblies is performed through electrical connection between the rail type socket (200) and positive electrodes of battery cells (100) constituting an adjacent first battery cell assembly via connection members (300), and a battery pack including the same.