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Battery Cell Connection Technology: A Case Study of a Battery Module

• 2023-12-11

Battery Cell Connection Technology: A Case Study of a Battery Module (JADE BUSBAR)

I. Introduction

The battery module is a crucial component in electric vehicles and energy storage systems. It consists of multiple battery cells connected together through various methods to achieve the desired voltage and capacity. The connection technology used in these battery modules plays a crucial role in ensuring optimal performance, safety, and durability. In this paper, we will discuss the various methods of connecting battery cells in a battery module, with a focus on the pros and cons of each method. We will also provide a case study of a specific battery module to demonstrate the application of these connection technologies.

II. Methods of Connecting Battery Cells

1. Threaded Fasteners: The threaded fasteners, such as bolts and nuts, are commonly used to connect the battery cells. The fasteners are designed to securely hold the cells together and provide good electrical contact. However, this method can be time-consuming and requires regular maintenance to ensure proper tightening.
2. Cold Crimp: The cold crimp method involves compressing the battery cell terminals using a special tool. This method provides good electrical contact and is relatively quick to execute. However, the cold crimp connection may not be as reliable as other methods over time and may require regular replacement.
3. Welded Joint: The welded joint method involves melting the base metal of the battery cell terminals and joining them together. This method provides a strong and reliable connection but requires special equipment and skilled operators for proper execution.
4. Soldering: The soldering method involves applying a molten metal to the battery cell terminals. This method is relatively inexpensive and easy to execute but may not provide as strong a connection as other methods.

III. Case Study of a Battery Module

In this case study, we will examine a specific battery module that uses the welded joint method for connecting the battery cells. The module consists of twelve lithium-ion battery cells connected in series using welded joints. Each cell has a capacity of 100Ah and a voltage rating of 3.6V. The overall voltage rating of the module is 432V, providing sufficient power for most electric vehicles.

IV. Pros and Cons of the Welded Joint Method

The welded joint method offers several advantages for connecting battery cells in a battery module. Some of these advantages include:

1. High strength and reliability: Welded joints provide a strong and secure connection between the battery cells, ensuring optimal performance over the life of the battery module.
2. Elimination of mechanical stress: Welded joints eliminate mechanical stress on the battery cell terminals, reducing the risk of damage or failure over time.
3. High electrical conductivity: Welded joints provide excellent electrical conductivity, ensuring efficient energy transfer between the battery cells.
4. Easy to automate: Welded joints can be easily automated using special equipment, reducing the time and cost associated with manual connections.

However, the welded joint method also has some disadvantages, including:

1. Cost: The equipment and expertise required for welding can be expensive, increasing the cost of producing battery modules using this method.
2. Skilled labor: Welding requires skilled labor to ensure proper execution and connections, adding to the overall production cost.
3. Material compatibility: The welding process may not be suitable for all types of battery cell materials, limiting its application in some cases.
4. Potential for defects: Improper welding can lead to defects in the connection, reducing its reliability and durability.

V .Conclusion

In conclusion, the welded joint method is a reliable and effective method for connecting battery cells in a battery module, offering high strength, electrical conductivity, and automation potential. However, it requires special equipment and skilled labor, adding to the production cost. Other methods such as threaded fasteners, cold crimp, and soldering may offer cost-effective alternatives but may not provide the same level of performance or reliability as the welded joint method in some cases. The selection of the appropriate connection technology should be based on the specific application requirements, including performance, cost, and reliability.

Summarized By Jade