Battery Module Holder With Elastic Coupling for Controller Mounting
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Solution Overview
Problem
The fixing of battery control systems in battery modules using heat fusion or bolts increases assembly and quality control costs, and bolt structures reduce cell capacity, hindering cost-effective manufacturing and module capacity improvements.
Innovation Solution
A battery module design featuring a battery control unit fixed by a coupling portion integrally provided with a flat plate holder, utilizing elastic forces to secure bus bars and a battery controller, eliminating the need for heat fusion or bolting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heat fusion is used to fix the battery control system to the holder, then the battery control system is securely fixed, but assembly costs and quality control costs increase
Solution Approach 1:
The patent replaces the thermal field (heat fusion) with a mechanical field solution. The battery control unit is fixed to the holder through mechanical engagement features such as protrusions fitting into recesses, or snap-fit mechanisms, eliminating the need for heat fusion processes while maintaining secure fixation and reducing manufacturing complexity
Solution Approach 2:
The patent introduces a mechanical intermediary structure between the battery control unit and the holder. This intermediary consists of coupling features (protrusions, recesses, or fastening elements) that mediate the connection, providing secure fixation without requiring thermal processes or additional fasteners
2Reliability
If a bolt structure is used to fix the battery control system, then the battery control system is securely mounted, but cell capacity is reduced due to nut height
Solution Approach 1:
The patent merges the mounting function directly into the holder structure itself. The holder is designed with integrated coupling features (protrusions or recesses) that directly engage with the battery control unit, eliminating the need for separate fasteners like nuts and bolts, thereby avoiding space occupation and preserving cell capacity
Solution Approach 2:
The patent transitions from a vertical stacking arrangement (where nuts would occupy vertical space above cells) to a lateral engagement arrangement. The coupling features engage horizontally or in-plane with the holder, utilizing dimensional space that does not interfere with cell height or capacity
3Reliability
If conventional fixing methods are used, then the battery control system is securely attached, but assembly complexity and quality control requirements increase
Solution Approach 1:
The patent implements self-fixing features where the battery control unit and holder have complementary geometric features (protrusions and recesses) that automatically align and engage during assembly. This self-aligning mechanism eliminates the need for complex alignment procedures, specialized tools, or multiple assembly steps, thereby reducing assembly complexity while maintaining secure attachment
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 design stabilizes the battery control unit against shocks and vibrations, enhancing operational reliability and reducing manufacturing costs while 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
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.