Battery Module Hook-Coupled Busbar Assembly for Scalable Sensing
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Solution Overview
Problem
As the number of battery modules increases, the connection structure and communication structure become complicated, requiring a simpler and more robust coupling method for efficient sensing and electrical connections in battery modules, especially for high-power applications like electric vehicles.
Innovation Solution
A battery module design featuring sub-battery modules with a cell stack, busbar assembly, insulating pads and covers, and a sensing assembly, where the upper cover includes through-holes for exposing parts and a busbar assembly with a hook-coupling mechanism for robust and simple connections, facilitating efficient electrical and communication links between battery cells and sensing components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of battery modules is increased to meet high power requirements, then the power capability is improved, but the connection structure and communication structure become complicated
Solution Approach 1:
The battery module is divided into multiple sub-battery modules, each with its own cell stack and sensing assembly. This segmentation allows the system to scale power capability by adding modules while keeping each module's internal structure simple and manageable, thus reducing overall connection complexity.
Solution Approach 2:
The upper cover is designed with through-holes that serve multiple functions: providing passage for sensing assemblies, enabling connection between sub-battery modules, and facilitating both electrical and communication connections. This multi-functionality reduces the need for separate dedicated structures for each function.
2Reliability
If traditional connection structures are used for sensing assemblies, then electrical connection is achieved, but the coupling structure becomes complicated and less robust
Solution Approach 1:
The upper cover integrates multiple functions into a single component: it provides structural coverage, creates connection passages through through-holes, and enables both electrical and communication connections. This merging eliminates the need for separate coupling structures, simplifying the overall design while improving reliability.
Solution Approach 2:
The through-holes in the upper cover act as intermediaries that facilitate connections between sub-battery modules and sensing assemblies. These holes provide a straightforward pathway for connecting components without requiring complex coupling mechanisms, thus simplifying the structure while ensuring reliable connections.
Data Source
AI summary
A battery module is disclosed. In some implementations, the battery module includes: first and second sub-battery modules respectively including a cell stack including a plurality of battery cells and a sensing assembly sensing a state of the plurality of battery cells and an upper cover covering upper portions of the first and second sub-battery modules, wherein the upper cover includes a plurality of through-holes exposing portions of the first and second sub-battery modules, respectively.