Segmented Battery Module Connecting Component for Reliable Welding
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Solution Overview
Problem
In battery modules, nonuniform gaps between connecting components and electrode terminals can lead to unreliable connections due to insufficient welding, which may result in detachment under expansion forces.
Innovation Solution
A battery module design featuring a connecting component with a split structure, including a first and second fixed connecting piece, where the first piece has a recess and the second piece has a protrusion, allowing for engagement and adjustment to compensate for height errors, ensuring reliable connections and preventing detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single connecting component is used to connect electrode terminals, then the structure is simple, but the connection reliability deteriorates due to insufficient welding caused by nonuniform gaps
Solution Approach 1:
The connecting component is divided into a first connecting piece and a second connecting piece, each independently connected to electrode terminals. This segmentation allows each piece to maintain reliable welding contact despite height variations in batteries, resolving the contradiction between structural simplicity and connection reliability.
Solution Approach 2:
The first and second connecting pieces are arranged in different spatial dimensions (stacked configuration), allowing them to compensate for height errors in the thickness direction while maintaining reliable electrical connection. This dimensional arrangement enables reliable connection without requiring complex adjustment mechanisms.
2Ease of manufacture
If the connecting component is made as a single piece, then the manufacturing process is simple, but the connection strength deteriorates under expansion force
Solution Approach 1:
The connecting component is segmented into multiple pieces with engagement structures (recess and protrusion) that allow easy assembly while distributing mechanical stress. This maintains manufacturing simplicity while significantly improving connection strength to resist battery expansion forces.
Solution Approach 2:
The engagement structure between the first and second connecting pieces is designed with a recess and protrusion that preliminarily position and secure the components before final welding. This preliminary mechanical engagement ensures proper alignment and prevents detachment under expansion force.
3Manufacturing precision
If the connecting component uses a fixed rigid structure, then the manufacturing precision requirement is low, but the adaptability deteriorates due to height errors in batteries
Solution Approach 1:
The connecting component is divided into stackable segments (first and second connecting pieces) that can accommodate height variations. Each segment maintains standard manufacturing tolerances while the stacked configuration provides adaptability to battery height errors through the engagement structure.
Solution Approach 2:
The engagement structure between connecting pieces allows for controlled movement and adjustment in the thickness direction, enabling the rigid connecting pieces to adapt to height variations while maintaining stable electrical connection. This dynamic adjustment capability compensates for manufacturing precision limitations.
Data Source
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AI summary
The present disclosure provides a battery module. The battery module includes a plurality of secondary batteries stacked along a thickness direction, a top of each secondary battery being provided with an electrode terminal; and a connecting component provided at the top of the secondary battery, the connecting component being connected to at least two electrode terminals for electrically connecting at least two secondary batteries. The connecting component includes a first fixed connecting piece and a second fixed connecting piece, and along an extending direction of the connecting component, the first fixed connecting piece matches and is engaged with the second fixed connecting piece. The present disclosure solves the problem of the unreliable connection between the connecting component and the electrode terminal.