Battery Module Controller Mounting Using Elastic Coupling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The use of heat fusion or bolt structures for fixing battery control systems in battery modules increases assembly and quality control costs, and bolt structures can reduce cell capacity, hindering cost-effective manufacturing and module capacity improvements.
Innovation Solution
A battery module with a battery control system that is fixed using a coupling portion integrally provided with a flat plate holder, employing elastic forces to secure the battery controller, eliminating the need for separate heat fusion or bolting processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heat fusion is used to fix the battery control system, then the battery controller is securely attached to the holder, but assembly costs and quality control costs increase
Solution Approach 1:
The patent replaces the thermal field (heat fusion) with a mechanical field solution using a coupling portion with elastic bodies. The elastic bodies generate elastic force to press the battery controller against the holder, achieving secure fixation without thermal processing. This substitution eliminates the need for heat fusion equipment and associated quality control procedures, reducing manufacturing costs while maintaining reliable attachment.
2Reliability
If a bolt structure is used to fix the battery control system, then the battery controller is securely attached to the holder, but cell capacity is reduced due to nut height
Solution Approach 1:
The patent transitions from a vertical stacking approach (bolts and nuts extending in the height direction) to a lateral coupling approach. The coupling portion extends in the width direction of the holder, with elastic bodies pressing horizontally against the battery controller. This dimensional change eliminates the need for vertical space occupied by nuts, preventing reduction in cell capacity while maintaining secure fixation through elastic force.
3Reliability
If heat fusion or bolting is used to fix the battery controller, then secure attachment is achieved, but the structure becomes complex and manufacturing becomes difficult
Solution Approach 1:
The patent merges the holder and the coupling portion into a single integrated component. The coupling portion is formed as an integral part of the holder body, eliminating the need for separate fastening components like bolts, nuts, or separate mounting brackets. This integration simplifies the overall structure, reduces the number of parts, and facilitates manufacturing while maintaining reliable attachment through the elastic force generated by the coupled structure.
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 solution stabilizes the battery control unit during shocks or vibrations, enhancing operational reliability and stability of the battery pack, while reducing manufacturing costs and maintaining module capacity.
Implementation Method 1
at least one coupling portion protruding from the flat plate holder in a third direction perpendicular to the first direction and the second direction, and configured to apply an elastic force in one of the first direction or the second direction
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A battery module includes: a battery array including a plurality of battery cells connected by a plurality of bus bars, and having a length in a first direction and a width in a second direction perpendicular to the first direction; a flat plate holder on the battery array to fix the bus bars; at least one coupling portion protruding from the flat plate holder in a third direction perpendicular to the first direction and the second direction, and to apply an elastic force in one of the first direction or the second direction; and a battery controller on the flat plate holder and fixed to the coupling portion by the elastic force, the battery controller to detect operating states of the battery cells and individually control the battery cells.