Battery Module Cases Integrating Bus Bars and Sensors
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Solution Overview
Problem
Middle- or large-sized battery modules face challenges with low mechanical strength, complex assembly processes, and increased size due to the need for multiple coupling and connection members, as well as complications in mounting sensing units for overvoltage, overcurrent, and overheating protection, which affect safety and efficiency.
Innovation Solution
A compact battery module design where a battery cell stack is fixed within module cases with integrated sensing members and a battery management system, using high-strength cell covers to restrain expansion and contraction, and simplifying assembly by eliminating the need for multiple connection members, while allowing for easy heat dissipation and secure electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple coupling and connection members are used to assemble battery cells, then the battery module can be constructed with proper mechanical strength and electrical connections, but the assembly process becomes complex and the overall size increases
Solution Approach 1:
The module case integrates both mechanical coupling and electrical connection functions into a single component. The case includes coupling protrusions that engage with battery cell edges for mechanical support, while simultaneously incorporating bus bars that extend through the case to provide electrical connections to battery terminals, eliminating the need for separate connection members
Solution Approach 2:
The module case serves multiple functions: it provides mechanical support and structural integrity through coupling protrusions, enables electrical connections through integrated bus bars, offers thermal management pathways, and provides protection for battery cells. This multi-functional design reduces the number of separate components needed
2Reliability
If sensing units are added for overvoltage, overcurrent, and overheating protection, then the safety of the battery module is improved, but the device complexity and assembly difficulty increase
Solution Approach 1:
The sensing units are integrated into the module case structure rather than being separate components. Temperature sensors are positioned within the case to monitor battery heat, while the BMS is mounted on the case and electrically connected to battery terminals through integrated pathways, consolidating safety functions into the existing structural framework
Solution Approach 2:
The BMS automatically monitors battery parameters and controls charging/discharging operations without requiring external intervention. The sensing units continuously detect temperature, voltage, and current conditions, and the BMS responds autonomously to maintain safe operating conditions, reducing the need for complex external control systems
3Weight of stationary object
If a compact battery module design is implemented to reduce weight and size, then the spatial utilization is improved, but the mechanical strength may be compromised
Solution Approach 1:
The module case is designed as a thin-walled structure that provides adequate mechanical protection while minimizing weight. The case includes strategically positioned coupling protrusions and reinforcement features that maintain structural integrity despite the reduced wall thickness, achieving a balance between weight reduction and mechanical strength
Solution Approach 2:
The module case utilizes composite material construction combining different materials with complementary properties. The case may incorporate high-strength, low-density materials that provide adequate mechanical strength while minimizing weight, and the integration of multiple materials allows optimization of both weight and strength characteristics
Data Source
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AI summary
Disclosed herein is a middle- or large-sized battery module comprising: a battery cell stack including a plurality of battery cells or unit modules electrically connected with each other, the battery cells or unit modules being erected in the lateral direction; a first module case constructed in a structure to entirely surround one side end of the battery cell stack and to partially surround the upper and lower ends of the battery cell stack, the first module case being provided at the front part thereof with external input and output terminals; a second module case coupled with the first module case, the second module case being constructed in a structure to entirely surround the other side end of the battery cell stack and to partially surround the upper and lower ends of the battery cell stack, the second module case being provided at the front part thereof with bus bars for connecting electrode terminals of the battery cell stack to the external input and output terminals; a sensing member mounted to the first module case or the second module case; and a battery management system (BMS) mounted to the first module case or the second module case, while being connected to the sensing member, for monitoring and controlling the operation of the battery module.