Side-Terminal Battery Module Structure for Dense, Easier Assembly
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Solution Overview
Problem
Existing battery modules with side-terminal cells face challenges in achieving high energy density while ensuring simplified assembly and improved load transferring capabilities, particularly in cell-to-pack designs, which are cumbersome to assemble and disassemble.
Innovation Solution
A battery module design featuring a stack of battery cells with side terminals connected by first and second busbars, arranged between first and second beams, allowing for simplified assembly and enhanced load transfer capabilities through the use of hardcase structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If cell-to-pack design is used to achieve high energy density, then energy density is improved, but assembly complexity increases
Solution Approach 1:
The battery module is segmented into a stack of battery cells arranged in a row, with each cell having a standardized hardcase structure. This segmentation allows for modular assembly while maintaining high energy density, as each cell can be independently manufactured and then stacked together with busbars to form the complete module.
2Strength
If traditional battery module assembly is used, then structural integrity is maintained, but assembly time increases
Solution Approach 1:
The battery cells are pre-assembled into a stacked configuration with the hardcase structures and terminal sides aligned before final assembly. The busbars are prepared in advance to connect the terminals. This preliminary arrangement of components significantly reduces the time required for final assembly while maintaining structural integrity through the standardized hardcase design.
3Quantity of substance
If side-terminal cells are used, then energy density is improved, but load transfer capability deteriorates
Solution Approach 1:
The hardcase structures of adjacent battery cells are merged together to form a unified structural framework. The busbars connecting the terminals also serve dual functions: electrical connection and mechanical load transfer. This merging of structural and electrical functions improves load transfer capability while maintaining the high energy density benefits of side-terminal cell configuration.
Data Source
AI summary
A battery module includes: a stack of battery cells each comprising terminals at opposite ends of a hardcase; first beam having a first opening; and a first busbar. The first beam is arranged parallel to the stack direction with end pointing into and against the stack direction. The first terminal of each battery cells faces the first beam, and the first busbar electrically connects the first terminals of at least two of the battery cells and is arranged between the stack and the first beam. The first opening is aligned with a position at where the first busbar is connected to the first terminals.