EV Battery Pack Assembly Methods & Design Optimization

Battery pack design to improve energy density, reduce space loss, enhance safety against thermal events, and enable direct battery cell mounting without intermediate modules. The pack has a housing with an inner space for cell cases containing the cells. The cells are directly mounted in the pack instead of being pre-assembled into modules. The cell cases have covers with insulating blocks to isolate the electrodes. This allows exhaust gases to vent through the slots. The pack case has frames and a removable drain cover to guide exhaust. The cell cases are stacked in the pack with the drain covers removed. This direct cell mounting eliminates module housing and simplifies assembly. It also allows the pack to be more compact and reduces space loss compared to module-based packs. The exhaust venting through the insulating blocks helps contain thermal events by preventing pressure buildup and preventing fire spread between cells. The removable drain cover allows pack venting during

Source

A method for assembling a battery cell core to improve battery volume and avoid the need for connecting tabs while ensuring stable welding. The assembly method involves: 1. Placing a battery tab against a battery electrode without connecting tabs. 2. Ultrasonically welding the tab to the electrode using a welding tip with a raised projection. 3. Applying pressure to the welded tab and electrode using a compression mold. This molding step compresses the tab and electrode together under pressure to create a strong welded joint. The compression molding replaces the need for connecting tabs between the tab and electrode. By eliminating connecting tabs and compressively molding the tab and electrode, the battery core can have increased volume without the added weight and space requirements of connecting tabs.

Source

Battery assembly method to reduce short circuits in lithium-ion batteries by improving voltage resistance at the separator cut edges. The method involves stacking the electrode sheets with the separator in a Z-shape, with the starting and ending edges covered by the positive sheet. This ensures the cut edges are on the same side when assembled. This stabilizes the cut edges and prevents short circuits when the battery is heated during manufacture. It avoids the need for coatings or additives to improve separator voltage resistance.

Source

A method to manufacture lithium-ion batteries that improves battery assembly efficiency and space utilization while preventing internal component movement. The method involves fixing the positive and negative terminals to the electrode tabs before encapsulating the battery. This prevents the electrode components from shifting during sealing. The terminals are directly connected to the tabs instead of using separate terminal posts. This allows the electrode components to protrude from the battery cover at a controlled height for better electrical contact. The fixed terminals and adjusted component heights prevent displacement issues during battery operation.

Source

A new method for assembling square lithium batteries that addresses issues with traditional cylindrical battery assembly. The method involves a sequence of steps for accurately positioning and sealing components, exhausting internal gas, and filling electrolyte in a square battery format. This involves using fixtures to hold components in place during assembly, sealing the battery edges before filling electrolyte, exhausting gas through specialized valves, and stacking cells in a square configuration. This improves assembly accuracy, prevents external gas entry, reduces electrolyte loss, and simplifies stacking compared to cylindrical batteries.

Source

An improved method for assembling large cylindrical aluminum shell batteries with reduced leakage and internal damage risks. The assembly process uses continuous penetration welding instead of resistance welding or ultrasonic torque welding to join the positive electrode case to the aluminum shell. This avoids high heat generation that can burn the diaphragm and create metal shavings. Additionally, the assembly sequence is modified to prevent top leakage by inserting the electrode stack into the shell before sealing the top. This eliminates the need for liquid injection through the top pole, which can leak. The bottom leakage risk is reduced by using a special bottom sealing gasket.

Source

Battery cell design with simplified assembly and reduced short circuit risk compared to conventional cells. The cell has a housing, battery assembly, cover, and current collector. The housing has an area around the opening that can be laser welded from the outside. This allows the cover and collector to be joined to the housing in that area without internal welding. This simplifies assembly and prevents metal dust from welding inside the cell. The external welding also facilitates electrical connection between the collector and housing.

Source

Battery cell design to improve safety and overcurrent capability by reducing internal resistance and welding defects. The cell has a case, electrode assembly, end cover, and current collecting member. The end cover seals the cell opening. The current collector is installed between the tab and cover, allowing welding to join them. This avoids uneven tab surfaces that cause welding defects. A protrusion on the cover supports the tab. The collector also has escape recesses to prevent welding the cover. The design reduces internal resistance by connecting current paths through the tab layers. It also improves uniformity and reduces welding defects.

Source

Battery cell design with improved reliability and reduced manufacturing complexity. The battery cell has a locked protective film around the electrode assembly that is secured to the insulating member. This prevents issues like film separation or stringing during assembly. The film has features like holes and extensions that engage the insulating member. The film locks to the insulating member using a pawl or boss. The locked film prevents film separation and stringing. This is achieved by a manufacturing method where the film is inserted around the assembly, locked to the insulating member, then the assembly is enclosed in the cell housing.

Source

Battery pack assembly for improved safety and assembly efficiency compared to conventional battery packs. The assembly has the battery cells connected in series/parallel using a circuit board between the cells and cases. This reduces the number of connectors compared to directly connecting the cells. The explosion-proof valve is on one end of the cell near the upper case and the electrical connection is on the other end near the lower case. This separates thermal and electrical management areas for improved safety by preventing electrical shorts during thermal runaway. The circuit board also has sensors to monitor cell parameters for protection.

Source

Battery cell manufacturing method and apparatus to prevent venting and deformation during initial charging. The method involves placing the battery can with the electrode assembly and electrolyte in an evacuated chamber, precharging the cell in the chamber, and exhausting the gases generated during precharging into the chamber. This prevents internal pressure buildup and external deformation during initial charging. The exhaust chamber can be sealed or have an inert gas injection system. The design allows scaling up battery cell capacity without venting issues.

Source

Battery design to improve assembly efficiency while maintaining safety. The battery has a support that separates the internal box into chambers. One chamber holds a pressure relief mechanism on the battery cell, and the other chamber holds the rest of the cell and a binder. This allows fixing the cell and binder together in the box while leaving the relief mechanism unobstructed. The support holds the cell steady and prevents binder from entering the relief chamber. This ensures stability and prevents dislodging of the relief mechanism during assembly. The design improves assembly efficiency by allowing multiple cells to be packed tightly together with fixed connections while still allowing functional relief mechanisms.

Source

Cylindrical battery assembly method and battery design that improves overcurrent capacity and reduces internal resistance. The method involves insulated and sealed installation of the positive pole in the housing, with a groove and riveting ribs. The positive current collector engages the groove. This provides larger welding area and thinner pole for lower resistance. The riveting block strengthens the positive side. The sealing and insulation between pole and housing prevent shorts.

Source

Battery design for electric vehicles that improves cooling and protection compared to conventional batteries. The battery has cells with conductors connected to busbars covered by insulation. The first busbar is on one side of the cells and the second busbar on the opposite side. This allows cooling from multiple directions through the busbars, preventing hotspots. It also shields the cells from external impacts since the busbars are not aligned.

Source

Battery cell design to improve safety and lifetime by preventing internal electrolyte leakage. The cell has a pressure relief mechanism that activates when pressure or temperature reaches critical values. It also has an insulating member between the cap and electrode assembly. This insulator covers the pressure relief mechanism when the cell is impacted, preventing accidental activation. A passage connects the cell interior to the insulator gap. When pressure builds, the relief mechanism vents through this gap instead of leaking internally. This avoids electrolyte impacting the relief mechanism. The insulator also stops electrolyte flowing into the gap when the cell shakes.

Source

Battery cell design to improve safety and performance. The battery cell has a housing with an opening, and an end cap that can be joined to the housing using laser welding. The end cap has a convex protrusion that separates it from the tab inside the housing. This prevents laser light from passing through gaps during welding and burning internal components. The tab connects to a current collector that bridges the gap and provides uniform current flow to the end cap. The larger housing size improves flow capacity. An electrode terminal is installed in a hole on the bottom wall to access the electrodes.

Source

Battery cell design that improves safety by preventing explosions during thermal runaway. The cell has a diversion channel between the battery housing and cover that guides a reinforcement material. This channel is formed by an insulator with features that abut against the housing and cover walls. Injecting a thermosetting prepolymer into the channel creates a reinforcement that connects both walls. This enhances the weld strength between the housing and cover, making it greater than the pressure relief valve's threshold. So the valve releases pressure before the housing ruptures.

Source

Battery energy storage device for vehicles that improves use safety compared to conventional designs. The device has a lower shell, upper shell, and battery cell assembly sandwiched between. The battery cells have poles and explosion-proof valves below the cells instead of above. This prevents internal cell failures from erupting through the upper shell and into the vehicle cabin. It also allows thermal runaway to vent downward into the lower shell instead of upward. This reduces the risk of cabin fire or damage from exploding cells. The lower shell can also contain cooling plates integrated with the cells for improved thermal management.

Source

Simplifying the design of battery cells to reduce size and improve safety. The battery cell has a housing, electrode assembly, end cover, and flexible conductor. The electrode assembly has a first tab at the end near the opening and a second tab at the far end. The end cover closes the opening and connects to the first tab. A flexible conductor connects the second tab to the end cover. This allows the positive and negative tabs to be on the same side of the electrode assembly. The flexible conductor prevents short circuits. It also allows the housing to have smaller openings, reducing size. The flexible conductor can pass through the electrode assembly center hole.

Source

Battery cell and module design to improve assembly efficiency and prevent deformation during charge/discharge cycling. The cell has an electrode assembly with negative electrode in a compressible guide member and positive electrode in another compressible guide member. This allows the expanding/contracting electrodes to compress the guides instead of deforming the cell housing. The guides are made of elastic material that compresses and expands with the electrodes. This prevents housing deformation and assembly issues when repeated charging/discharging causes expansion/contraction of the electrodes. The compressible guides also improve module assembly efficiency by eliminating the need for external expansion gaskets between the modules.

Source

Battery cell design and assembly method to prevent damage during cell insertion and compression. The battery cell has an electrode stack divided into sub-stacks separated by a compressible pad. The cell housing has a removable cover. To assemble, the sub-stacks are inserted with the compressible pad in its uncompressed state. This prevents relative movement between the sub-stacks and busbars during compression. The cover is then attached. By compressing the pad before insertion, the sub-stacks can be loaded without damaging connections.

Source

Cylindrical battery design with improved connection method between the positive and negative electrode terminals and the internal electrode group. The battery has a threaded connecting rod that passes through the positive and negative terminal pieces and connects to the internal pole group. This allows tightening the rod to compress the terminals onto the pole ends, providing a better connection and larger contact area compared to laser welding. The threaded rod also prevents air holes or explosions during assembly. The battery module and pack configurations use multiple connected batteries for increased performance and capacity.

Source

Vacuum liquid injection sealing system and method for battery assembly that prevents air and water vapor from entering the battery during assembly to avoid adverse reactions like swelling. The system has a vacuum chamber connected to an electrolyte tank and return tank. The battery components are inserted, vacuum pumped, electrolyte injected, vacuumed again, and then pressed together. This allows filling the battery with electrolyte in a vacuum to prevent outside air from entering.

Source

A battery pack design with internal series connection of cells without external connectors that improves energy density and reliability compared to external connections. The cells are arranged in a frame with covers, a core cavity, and accommodating cavities. The cells have tabs that protrude into the accommodating cavities. A tab protector covers the tabs. Pole covers connect to the cells and have sensors. The frame, covers, and pole covers are sealed to prevent electrolyte leakage. A valve on the frame prevents pressure buildup. The internal connection prevents electrolyte circulation between cells.

Source

A dry-process battery design that eliminates wet electrode preparation steps to improve energy density, safety, and environmental friendliness compared to traditional wet electrode batteries. The dry-process battery avoids wet processes like mixing solvents, coating, drying, and rolling by forming the electrode layers using fiber binding agents and radiation pressing. The dry electrode sheets are stacked and assembled directly into the battery cases without additional tab welding or laser sealing. This reduces pollution, energy consumption, metal dust generation, and solvent residue compared to wet methods. The battery also has separate upper and lower pole cores connected by thread sealing to further improve safety by avoiding internal short circuits.

Source

Battery cell design with improved electrical connection and environmental monitoring for enhanced safety and efficiency. The design includes a modified electrode assembly, end cap, and monitoring/sensing module. The electrode tabs are connected with conductive adhesive and welding instead of just welding, improving stability. The end cap has a monitoring module for detecting internal environmental conditions like temperature and voltage. The module communicates with a sensing module on the end cap to provide early warning or external communication. This allows detecting abnormal internal conditions and providing safety measures. The integrated monitoring/sensing reduces assembly steps compared to separate modules.

Source

Battery pack and automobile design with inverted battery cells to improve safety by preventing ejected hot gases from a thermal runaway battery cell from entering the passenger cabin in case of failure. The inverted cell orientation has the positive and negative terminals at the bottom instead of the top. This allows the explosion-proof vent to be facing downwards away from the cabin. The cells are mounted on an insulating tray with a liquid cooling system passing through. This configuration prevents hot gases from a failed cell from being ejected towards the passenger cabin if a thermal runaway occurs.

Source

Battery cell module and electric vehicle design to improve battery safety by preventing runaway cells from causing chain reactions. The design features venting mechanisms in the cell tab, adapter plates, and pole to allow airflow out when a cell overheats. This prevents pressure buildup and explosions that can spread to nearby cells. The vented components also flush out when a cell explodes to create circuit breaks and stop further reactions.

Source

Method to assemble high internal string count bipolar lithium-ion or sodium-ion batteries with improved power density and safety compared to single cell batteries. The method involves stacking multiple inner string units made of electrode-coated current collectors with opposite polarities between them. The stack is then enclosed in a bipolar housing with electrolyte filled between the strings to prevent internal short circuits. This allows higher voltage and power by internally connecting multiple cells, while the solid electrolyte prevents ion leakage. The stack can have a large number of inner strings for high capacity.

Source

A power battery pack for electric vehicles that improves energy density and safety compared to conventional packs. The pack has a unique design for the battery cells that reduces height and prevents internal cell failures from damaging the pack and vehicle. The cells have the positive and negative lugs on the sides instead of the top. This frees up space above the cells for higher energy density. It also prevents internal cell failures from spraying hot gas and debris out the top and damaging the pack components or vehicle below. The cells may have their own venting to prevent pressure buildup. The pack also has an external electrical module outside the cell stack that provides functions like battery management, current collection, and protection. This allows easy maintenance and replacement compared to integrated modules.

Source

CTC (Cell to Chassis) battery system for electric vehicles that reduces weight, saves space, and improves range compared to traditional pack designs. The CTC system integrates the battery cells directly into the vehicle chassis without using a separate battery enclosure. This is achieved by using a specialized buffer assembly between the cells and chassis that contains pressure relief holes. The cells are installed into the holes in the buffer assembly and sealed against the chassis. This allows the cells to expand and contract during charge/discharge without separating from the chassis. The buffer assembly provides thermal runaway protection and prevents explosion ejection into the passenger compartment.

Source

Battery module design to improve safety and maintainability of electric vehicle battery packs. The module has a unique cell arrangement where the cells are inverted with terminals and valves at the bottom. This allows the module to be mounted with the cells facing downward, preventing impacts on the passenger compartment if cells vent. It also enables easier access for service. The inverted cell arrangement is supported by structures and thermal protection at the bottom. The module can be sealed with adhesive instead of screws for improved water resistance.

Source

High-safety soft pack battery module for electric vehicles that prevents thermal runaway propagation and improves overall battery safety. The module design features a multi-part shell enclosure around the battery cells. The enclosure has pressure relief holes and grooves to vent high-temperature gases generated by a thermal runaway cell. The relief features allow gases to escape and prevent them from accumulating and further heating adjacent cells. This prevents domino cell failures and thermal propagation.

Source

Battery module design for electric vehicles that improves safety by preventing thermal runaway propagation. The module has features like slots in tabs and adapter plates that allow airflow if a cell overheats. This prevents pressure buildup and explosion in adjacent cells. The poles have an explosion-proof valve that flushes air and the busbar when a cell goes rogue. This isolates the faulty cell and prevents chain reaction.

Source

Battery module with improved energy density and safety by connecting battery cells of different chemistries in series. The module has a first-type cell with lower volume energy density but higher capacity compared to a second-type cell with higher volume energy density but lower capacity. This allows maximizing the overall energy density while ensuring safety by balancing the capacity ratios. The cells are connected in series with the first-type cell before the second-type cell. This configuration improves energy density and safety compared to using just high-energy cells or just high-capacity cells. It also allows utilizing higher energy density cells without compromising overall energy output or safety.

Source

Battery assembly method and lithium battery design to improve overcurrent capability. The method involves connecting the battery components in a specific way to avoid reducing the current collection area of the negative electrode during assembly. This improves overcurrent capability. The battery assembly steps include: 1) Welding the positive terminal to the pole group. 2) Welding the negative terminal to the electrode group. 3) Welding the aluminum column to the positive terminal. This allows the pole group to be inserted into the casing with the aluminum column matching the central hole of the positive terminal. This fixes the pole group to the casing without obstructing the negative electrode end. The negative electrode current collector is welded to the casing inner wall.

Source

Battery cell unit for electric vehicles that improves safety and reduces cost compared to conventional battery packs. The unit is modular and can be stacked in multiple units on the vehicle chassis instead of a single large pack. This simplifies cell packaging and reduces connections. The chassis has exhaust channels between units to prevent high-temperature gas buildup that could ignite. This avoids gas spreading between cells and improves safety.

Source

Battery cell design with improved safety and simplified assembly. The cell has a housing, electrode assembly, end cover, and current collecting member. The collecting member connects the electrode assembly and housing internally, allowing the end cover to be sealed without contacting the assembly. The housing and end cover are hermetically joined. This allows the collecting member to be installed inside the housing before sealing the end cover. The collecting member's lower melting point compared to the housing enables easier welding inside the housing. It also reduces the risk of explosion by preventing internal pressure/temperature buildup in the housing from propagating.

Source

High-voltage battery for electric vehicles that prevents electronic component damage during thermal events like overheating. The battery has a housing with separate compartments for electrical components and battery cells. A partition separates the compartments. If a thermal event occurs in one compartment, the partition prevents it from spreading to the other compartment. This isolates the affected component and prevents catastrophic failure of the entire battery.

Source

High-voltage battery for electric vehicles that reduces the risk of battery cell overheating propagation without using separate shielding elements. The battery module has multiple cell assemblies, with some having cells having higher flammability and some having lower flammability cells in between. The lower flammability cells act as propagation barriers to prevent overheating in one cell from spreading to other cells.

Source

Battery module design for electric vehicles with improved safety in high voltage, multi-cell configurations. The module has at least three end plates, side plates, a battery core, connecting sheets, a safety disconnect, and an upper cover. The end plates reinforce the module structure and prevent internal cell failure propagation. The safety disconnect has a middle pole, left and right end connectors, and a middle connector. It isolates the middle section of the module if voltage exceeds a safety limit. This prevents chain reactions from spreading. The end plates also have signal acquisition devices to monitor module health.

Source

A method to improve the performance of secondary batteries by optimizing the electrode assembly. The method involves patterned bonding of the interface between electrodes and separators in the assembly. This is done by locally heating and pressing the incomplete assembly to create a bonded area and a non-bonded area. The electrolyte is then injected into the assembly, which penetrates the non-bonded area and fills the inside. This allows better electrolyte impregnation compared to full bonding. The bonded area prevents electrolyte leakage. Later, heating and pressing the entire battery bonds the non-bonded areas. This reduces interface gaps and improves battery cycling without unreacted areas.

Source

Battery cell with improved assembly and electrical connection stability compared to prior art designs. The battery cell separates the adapter assembly into two parts, one connected to the electrode terminal and the other connected to the electrode tab. During assembly, these parts are installed separately then joined together. This avoids bending the adapter multiple times on-site which can damage it. The fixed connection of each adapter part improves impact resistance compared to bendable adapters.

Source

Battery pack design to prevent thermal runaway propagation in electric vehicle batteries. The battery pack has explosion-proof assemblies on each cell that vent hot gases during cell failure. This prevents internal cell failure from spreading to other cells. Additionally, the pack has a first protective component around the module electrical connections. This component shields the connections from the high-temperature, high-pressure gases released during cell failure. This prevents melting and warping of the connections.

Source

Battery pack design for electric vehicles that enables improved safety and reliability by preventing chain reactions and explosion propagation between battery cells. The pack has a unique structure with a hollow protective beam extending along the pack's longitudinal axis. The cells are mounted on the panel and surrounded by the beam. This design allows explosive venting of individual cells through the beam if pressure builds up, preventing chain reactions between cells. The beam also provides mechanical strength and thermal management. The pack has improved safety and reliability by containing cell failures and preventing chain reactions.

Source

A secondary battery design with improved safety by preventing metal debris from entering the battery housing during assembly. The battery has a protruding adapter piece connecting the electrode terminal to the electrode assembly. The protruding adapter extends into the adapter sheet hole, allowing the electrode assembly to be installed first. External laser welding connects the adapter and terminal, avoiding metal chips entering the housing. This prevents short circuits and burning from debris.

Source

A battery pack for electric vehicles that reduces the risk of thermal runaway-induced fire and explosions. The battery pack design has the cells arranged vertically rather than horizontally to reduce the maximum expansion force. This allows using thinner end plates and reduces the overall pack size. The vertical orientation also reduces the number of cells in the stack, further reducing expansion forces compared to horizontal stacks. This mitigates the risk of explosive cell failure ejecting debris and flames upward towards the vehicle cabin.

Source

A method to assemble an energy storage device like a battery that improves safety without sacrificing performance. The method involves sealing the battery inside a housing with a recessed structure that forms part of the enclosed cavity. The recessed structure has a conductive portion. This allows electrical connection between the battery terminals and the housing while creating a weakened band in the recessed area. During expansion, the weakened band breaks instead of the entire tab, preventing over-pressure and power failure. The conductive portion ensures electrical continuity.

Source

Assembly method for lithium-ion battery packs that reduces metal particles entering the battery during assembly. The method involves welding a connecting piece between the battery cell and the top cover using ultrasonic welding. This step is done after laser welding the top cover and connecting piece. Laser welding is used first because it creates metal particles that can fall on the top cover and connecting piece, preventing them from entering the cell during ultrasonic welding. The connecting piece is vacuumed after laser welding to remove any metal particles. This prevents contamination of the cell during ultrasonic welding.

Source

Assembly and packaging process for a soft-packed lithium battery with high drop resistance to prevent electrolyte leakage and explosions when the battery is dropped or impacted. The assembly process involves fixing the battery core in place inside the shell using an adhesive. The packaging process involves coating the exterior of the pack with a flexible adhesive layer that adheres to itself. This self-adhering layer compresses and seals around the pack when it is dropped, preventing electrolyte leakage.

Source