Stacked Battery Cell Assembly With Insulation for Short-Circuit Prevention
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Solution Overview
Problem
The existing connection methods for battery cells are costly, time-consuming, and prone to short circuits, requiring complex molds and bolt holes, which affects safety and production efficiency.
Innovation Solution
A battery assembly that includes protection members such as insulation layers, high-temperature resistant layers, and adhesive layers to prevent short circuits between cells, allowing for secure bonding and stacking without the need for brackets or bolts, using adapting members with connecting parts and partition parts to accommodate tabs and ensure electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If battery cells are stacked and connected by brackets or fastening through bolts, then the connection is secure, but the development cycle and production cost increase due to requiring custom molds and bolt holes
Solution Approach 1:
The patent applies a universal protection film structure that can be used across different battery cell types and configurations without requiring custom molds or bolt holes. The film serves multiple functions: electrical insulation, mechanical protection, and structural support during stacking, eliminating the need for cell-specific connection designs and reducing development cycles.
Solution Approach 2:
The patent replaces the mechanical connection system (brackets and bolts requiring custom molds) with a film-based insulation and protection system. The protection film is applied directly to the battery cell surfaces and provides both electrical insulation and mechanical support during stacking, substituting complex mechanical fastening systems with a simpler film application process.
2Strength
If battery cells are stacked and connected by brackets or fastening through bolts, then the connection is secure, but the production cost increases due to requiring custom molds and bolt holes
Solution Approach 1:
The protection film structure serves multiple functions (insulation, protection, structural support) in a single component that can be universally applied across different battery cell types, eliminating the need for expensive custom molds and reducing production costs associated with cell-specific connection designs.
Solution Approach 2:
The patent replaces expensive mechanical connection systems requiring custom molds with a film-based system that can be applied through standard manufacturing processes, significantly reducing tooling costs and simplifying production.
3Ease of manufacture
If battery cells are stacked without protection members, then the production process is simpler, but short circuits may occur between tabs affecting safety
Solution Approach 1:
The patent introduces protection films as intermediary elements between battery cell tabs during stacking. These films provide electrical insulation to prevent short circuits while maintaining the simplicity of the stacking process. The films are applied to specific areas of the cells and serve as mediators that enable safe direct stacking without complex protection mechanisms.
4Reliability
If protection members are added to prevent short circuits, then safety is improved, but the device complexity increases
Solution Approach 1:
The protection films serve as simple intermediary elements that provide essential safety functions (electrical insulation and short circuit prevention) without adding complex structural components. The films are applied directly to cell surfaces and work passively to prevent short circuits, maintaining system simplicity while improving safety.
Solution Approach 2:
The patent uses thin film structures to provide protection against short circuits. These flexible films conform to the cell surfaces and provide electrical insulation without adding significant structural complexity or bulk to the battery assembly, maintaining simplicity while ensuring safety.
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
The solution prevents short circuits, enhances safety, reduces development cycles and costs, and eliminates the need for complex molds, enabling efficient and cost-effective production of battery modules.
Implementation Method 1
the at least one first protection member each further includes at least one adhesive layer
Data Source
AI summary
A battery assembly is provided. The battery assembly includes: at least one first battery cell, at least one second battery cell which is stacked with the first battery cell, and at least one first protection member configured for preventing short circuit between the first battery cell and the second battery cell. The first battery cell and the second battery cell each comprise tabs, and the tabs include a first tab and a second tab. One of the first tab and the second tab of the first battery cell is electrically connected to one of the first tab and the second tab of the second battery cell, to form a first series tab assembly.