Battery Module Cover with Integrated Conductor Tracks
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Solution Overview
Problem
Existing battery modules face challenges in reducing weight and achieving efficient construction and connection technology, particularly in the mechanical design of battery packs, where the battery module covers are cumbersome and require separate sensor cables, leading to increased weight, cost, and reduced space efficiency.
Innovation Solution
Integration of conductor tracks within the battery module cover that are electrically conductive and connectable to sensors, eliminating the need for separate sensor cables, and using a three-dimensional injection-molded circuit carrier with patterned metalization and seals, allowing for efficient production and improved insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate sensor cables are used in the battery module cover, then electrical connection to sensors is achieved, but weight and device complexity increase
Solution Approach 1:
The patent combines the sensor cable function with the battery module cover by integrating conductor tracks directly into the cover structure. This merging eliminates separate sensor cables while maintaining electrical connection reliability to sensors, thereby reducing weight and device complexity.
2Reliability
If separate sensor cables are used in the battery module cover, then electrical connection to sensors is achieved, but device complexity and cost increase
Solution Approach 1:
The patent merges the sensor cable function with the battery module cover by integrating conductor tracks directly into the cover structure. This integration reduces device complexity and cost while maintaining reliable electrical connections to sensors.
Solution Approach 2:
The battery module cover is designed to serve multiple functions: it provides mechanical protection, electrical insulation, structural support, and electrical connection pathways for sensors. This multi-functionality eliminates the need for separate sensor cables, reducing device complexity.
3Ease of manufacture
If conventional battery module covers are used without integrated conductor tracks, then manufacturing is simpler, but moisture protection and electrical insulation are reduced
Solution Approach 1:
The patent employs composite material structures in the battery module cover, combining insulating materials with integrated conductor tracks. This composite approach maintains ease of manufacture through injection molding while providing enhanced moisture protection and electrical insulation compared to conventional covers.
4Volume of moving object
If battery cells are arranged close together to reduce installation space, then volume efficiency improves, but mechanical design and connection technology become more challenging
Solution Approach 1:
The battery module cover is designed as a multi-functional component that provides mechanical protection, electrical insulation, structural support, and integrated electrical connection pathways. This universal design simplifies mechanical design and connection technology while enabling compact arrangement of battery cells to reduce overall module volume.
Data Source
AI summary
A battery module comprises at least one battery cell including two battery cell terminals. The battery module further comprises a battery module cover configured for connection to the battery module to cover at least part of the battery module. Conducting tracks configured for connection to at least one sensor in an electrically conductive manner are integrated in the battery module cover.