Resilient Spring Interconnectors for Battery Module Assembly
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Solution Overview
Problem
The existing battery module technologies for electric vehicles face challenges in efficiently connecting and monitoring lithium-ion batteries, which are prone to temperature variations and require stable designs to withstand vibrational loads, leading to increased manufacturing costs and complexity.
Innovation Solution
A battery module design featuring resilient spring-type interconnectors that simultaneously conductively couple to the terminals of electrochemical cells, allowing for easy and reliable connection of circuit boards to cell terminals, using interconnection washers that can withstand high vibrational loads and provide secure connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional connection methods are used for battery cells, then manufacturing precision can be maintained, but assembly time and manufacturing costs increase significantly
Solution Approach 1:
The interconnector merges multiple functions into a single component: it provides electrical connection between battery cells, mechanical support for the circuit board, and structural stability against vibrational loads. This integration eliminates the need for separate connection elements, reducing assembly steps and time while maintaining manufacturing precision.
Solution Approach 2:
The interconnector serves multiple purposes simultaneously: it acts as an electrical conductor, a mechanical fastener, a circuit board mount, and a vibration dampener. This multi-functionality reduces the total number of components needed in the battery assembly, thereby reducing assembly complexity and cost while improving productivity.
2Reliability
If stable connection designs are used to withstand vibrational loads, then reliability improves, but device complexity and manufacturing costs increase
Solution Approach 1:
The interconnector incorporates a resilient spring-type design that dynamically adapts to vibrational loads. The elastic element deforms under vibration and returns to its original position, continuously maintaining electrical contact and mechanical stability without requiring complex rigid structures or additional damping components.
Solution Approach 2:
The interconnector changes its physical parameters (shape, position) in response to vibrational forces through the elastic element's deformation. This allows the connection to remain stable under varying load conditions without increasing design complexity, as the material properties and geometric design accommodate the changes.
3Quantity of substance
If lithium-ion batteries are used to increase charge density, then power and space efficiency improve, but susceptibility to temperature variations and manufacturing challenges increase
Solution Approach 1:
The interconnector acts as an intermediary between the battery cells and the external environment, providing a stable mechanical and electrical connection that isolates the lithium-ion batteries from external shocks and vibrations. The resilient design absorbs thermal expansion and contraction, protecting the temperature-sensitive lithium-ion chemistry.
4Measurement precision
If complex monitoring systems are added to track battery cell status, then measurement precision improves, but device complexity and manufacturing costs increase
Solution Approach 1:
The interconnector merges the electrical connection function with the circuit board mounting function. By integrating the circuit board directly onto the interconnector structure, the patent eliminates the need for separate mounting brackets, fasteners, and wiring harnesses, thereby reducing system complexity while maintaining precise monitoring capabilities.
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 design reduces assembly time and costs by enabling quick and stable connections between battery cells and circuit boards, improving the reliability and efficiency of battery modules while minimizing the risk of short circuits and enhancing temperature measurement accuracy.
Implementation Method 1
Each of the interconnectors is a resilient spring-type interconnector
Data Source
AI summary
A battery module includes multiple electrochemical cells, a circuit board, and multiple interconnectors. Each electrochemical cell includes a terminal. Each of the interconnectors is coupled to the circuit board and to a terminal of one of the electrochemical cells. Each of the interconnectors is a resilient spring-type interconnector.