Battery Module Connection Board Hooking Structure for Vibration Stability
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Solution Overview
Problem
Large-sized battery modules and packs face stability issues due to potential chain reactions among battery cells, which can lead to accidents like ignition and explosion, and external terminal configurations are prone to damage from external forces, necessitating a compact and secure fixing mechanism to enhance safety and minimize space occupation.
Innovation Solution
A battery module design featuring a connection board tightly fixed to the housing using bus bar supporting members with hooking protrusions and grooves, an end plate, and a top cover with coupling parts, ensuring secure attachment and resistance to vibrations and impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If external input and output terminals are installed with a small size outside the battery module to minimize space occupation, then space efficiency is improved, but the terminals are not tightly fixed and become prone to damage from external forces
Solution Approach 1:
The connection board is divided into multiple sections with individual fixing structures. Each section has hooking protrusions that engage with corresponding grooves on the housing, allowing the connection board to be securely fixed while maintaining a compact external terminal configuration. This segmentation enables localized reinforcement without increasing overall space occupation.
Solution Approach 2:
The fixing structures are nested within the connection board and housing assembly. The hooking protrusions are formed as integral parts of the connection board, and the hooking grooves are formed on the housing surface, creating a nested fixing mechanism that does not increase the external dimensions of the battery module while providing robust fixation.
2Quantity of substance
If a large number of battery cells are used to meet energy demands, then energy capacity is improved, but stability problems arise due to potential chain reactions among battery cells
Solution Approach 1:
The battery module uses a standardized connection board design that can be replicated across multiple cell groups. Each connection board section independently manages a specific group of battery cells, creating functional segmentation that limits the propagation of abnormal operations while maintaining high overall capacity through the use of many cells.
3Ease of manufacture
If the connection board is not tightly fixed to the housing, then assembly simplicity is improved, but defects such as welding part damage, cell lead breakage, and bus bar soldering cracks occur due to external force
Solution Approach 1:
The hooking protrusions and grooves are pre-formed as integral features of the connection board and housing during their respective manufacturing processes. This preliminary formation of fixing structures eliminates the need for separate assembly steps to create the fixation mechanism, maintaining assembly simplicity while ensuring precise alignment and secure connection when the components are assembled.
Solution Approach 2:
The hooking protrusions and grooves act as intermediary fixing elements between the connection board and housing. These intermediary structures provide a mechanical interface that securely connects the two components, preventing direct transmission of external forces to the welding parts and electrical connections, thereby maintaining connection integrity without complex assembly procedures.
Data Source
AI summary
A battery module according to an exemplary embodiment of the present invention includes: a housing receiving a plurality of battery cells and including a bottom plate and a lateral plate; and a connection board disposed at one end or both ends of the housing, wherein the connection board is bonded to the lateral plate. The lateral plate may include a plurality of bus bar supporting members, at least some among the plurality of bus bar supporting members having a hooking protrusion protruded upward. The connection board may include a hooking member having a hooking groove opened downward. Thus, the hooking protrusion may be inserted into the hooking groove in a state in which the connection board is bonded to the lateral plate.