Threaded Battery Cell Carrier for EV Module Assembly
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Solution Overview
Problem
The assembly and wiring of battery modules in electric vehicles are labor-intensive and costly due to the large number of individual battery cells, making maintenance, repair, and recycling difficult, and the high-temperature potting process risks damaging the cells.
Innovation Solution
A battery module design featuring a cell carrier with internal threads that complement the external threads on the battery cells, allowing for simple screw-in assembly and reducing the need for extensive wiring, along with integrated coolant channels and phase change materials for temperature management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If battery cells are joined using casting compound at high temperature, then good flow and wetting behavior is achieved, but battery cell degeneration occurs
Solution Approach 1:
The patent changes the temperature parameter of the joining process by introducing a temperature-compensated joining mechanism that adapts to different battery cell temperatures, allowing effective joining without subjecting cells to damaging high temperatures
Solution Approach 2:
The patent introduces a temperature-compensated joining mechanism as an intermediary between the joining process and battery cells, which mediates the temperature effects to achieve proper joining without cell degradation
2Power
If more than a thousand individual battery cells are coupled to form a battery module, then sufficiently high operating voltage is achieved, but manufacturing effort and production time increase
Solution Approach 1:
The patent segments the battery module assembly into standardized units with temperature-compensated joining mechanisms, allowing parallel assembly processes and reducing overall manufacturing time while maintaining the required number of cells for sufficient operating voltage
Solution Approach 2:
The patent implements preliminary temperature compensation measures during the joining process setup, which streamlines the assembly operation and reduces the time required for joining thousands of cells by eliminating the need for extensive temperature management during assembly
3Stability of the object's composition
If battery cells are encapsulated using potting compound, then mechanical stability is improved, but subsequent dismantling for maintenance or recycling becomes difficult
Solution Approach 1:
The patent employs a dynamic joining mechanism with temperature compensation that can be reversed or adjusted, allowing the battery cells to be securely joined during operation but easily separated when dismantling is required for maintenance or recycling
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 simplifies assembly, reduces production costs, enables easier maintenance and recycling, and provides effective temperature control for the battery cells, enhancing the reliability and service life of the battery module.
Implementation Method 1
a phase change material (phase change material, PCM) as a latent heat storage device
Implementation Method 2
a phase change material (phase change material, PCM) as a latent heat storage device
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a battery module (4) comprising at least one battery cell (14) and a cell carrier (16), wherein the battery cell (14) has a cylindrical cell housing (18) with an outer shell surface (28), wherein an external thread (32) is provided in the shell surface (28), and wherein the cell carrier (16) has at least one threaded bore (36) with an internal thread (38) into which the at least one battery cell (14) is screwed or can be screwed.