Battery Module Assembly With Integrated Sensing and BMS Access
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Solution Overview
Problem
Existing battery module assemblies face challenges due to increased cell thicknesses requiring new high-strength exterior members, vertically separated assembly fastening structures, and limitations in integrating a Battery Management System (BMS) for monitoring and control, as well as structural constraints with linear support protrusions and sensing assemblies.
Innovation Solution
A battery module assembly design that stacks unit modules horizontally, uses cartridge assemblies with adapters and sensing assemblies, and incorporates a cover member with pin/hole structures for secure connection, eliminating the need for additional partitions and allowing direct connection of the sensing assembly, while enhancing insulation and cooling efficiency through specific cell tab bending and surface pressure pads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-strength exterior members are manufactured newly to accommodate increased battery cell thicknesses, then the structural strength is improved, but the manufacturing cost and complexity increase
Solution Approach 1:
The battery module is divided into multiple unit modules, each with its own exterior members and fastening structures. This segmentation allows each component to be optimized independently, reducing the complexity of manufacturing large-scale integrated structures while maintaining overall structural strength.
Solution Approach 2:
The exterior members and fastening structures are designed to serve multiple functions: structural support, mechanical fastening, and integration of BMS components. This multi-functionality reduces the need for separate specialized components, thereby lowering manufacturing complexity and cost while maintaining strength.
2Adaptability or versatility
If assembly fastening structures are vertically separated, then the assembly flexibility is improved, but the structural integrity and manufacturing complexity are worsened
Solution Approach 1:
The fastening structures are vertically separated into distinct upper and lower portions, allowing independent positioning and assembly. This segmentation provides assembly flexibility while the standardized design of separated components reduces overall structural complexity.
Solution Approach 2:
The fastening structures utilize both vertical and horizontal dimensions for connection, with upper and lower fastening portions working in different spatial planes. This multi-dimensional approach enhances assembly flexibility while distributing structural complexity across different spatial dimensions.
3Reliability
If the BMS is provided on the rear of a lower case, then the monitoring and control function is achieved, but the accessibility for BMS A/S is lost
Solution Approach 1:
The BMS is extracted from its traditional fixed position on the rear lower case and repositioned to the front of the upper case. This extraction allows the BMS to maintain its monitoring and control functions while gaining improved accessibility for maintenance and service operations at the front of the module.
4Area of stationary object
If cartridge assemblies are configured to surround the entire outer surface, then the structural coverage is improved, but the adaptability to different sensing structures is limited
Solution Approach 1:
The cartridge assemblies provide comprehensive structural coverage across the entire outer surface, but with locally varied configurations at specific positions. This allows different sensing structures to be accommodated at different locations while maintaining overall structural integrity and coverage.
Solution Approach 2:
The cartridge assemblies are designed with universal mounting capabilities that can accommodate various sensing structures. The standardized interface and flexible configuration allow the same cartridge assembly design to work with different sensing technologies and arrangements.
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
Provided is a battery module assembly in which unit modules are stacked. Each of the unit modules includes: a plurality of battery cells; and a plurality of cartridge assemblies for respectively fixing the plurality of battery cells. The battery module assembly includes: a sensing assembly mounted to upper ends of the plurality of cartridge assemblies and assembled thereto; a front cover for covering front surfaces of the cartridge assemblies; and a connector coupled and fixed to the front cover. The connector includes: a connector body; and a first protrusion region that protrudes from the connector body. An upper sensing assembly connection hole is formed in an upper region of each of the cartridge assemblies.