Battery Cell Module Assembly With Integrated Busbar Sensing
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Solution Overview
Problem
Conventional battery modules face complex and time-consuming wiring processes for harness cables, making it difficult to achieve a simple and compact design, and there is a need for improved durability and safety in battery packs.
Innovation Solution
A cell module assembly with a simple connection and assembly structure featuring busbar plates and a sensing unit on a cell frame, where components for electrical connection and temperature/voltage sensing are centrally located, allowing for efficient heat dissipation and improved durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If harness cables with multiple cables and terminals are used to transmit voltage information, then voltage monitoring capability is improved, but wiring complexity and assembly time increase significantly
Solution Approach 1:
Multiple separate cable terminals are merged into a single busbar structure. The busbar integrates multiple connection points for voltage sensing into one unified component, eliminating the need for multiple separate cables and terminals while maintaining the ability to monitor voltage across multiple battery cells.
Solution Approach 2:
The busbar serves multiple functions simultaneously: it acts as an electrical connection component for voltage sensing, a structural support element, and a routing guide for the sensing unit. This multi-functionality reduces the overall number of components needed in the system.
2Ease of operation
If multiple design structures such as cable ties, cable holders, and wiring grooves are added to route and secure harness cables, then cable routing and securing are improved, but device simplicity and compactness deteriorate
Solution Approach 1:
Multiple separate routing structures (cable ties, cable holders, wiring grooves) are merged into the integrated busbar design. The busbar itself provides the routing path and securing function, eliminating the need for additional dedicated routing components.
Solution Approach 2:
The busbar performs both electrical connection and mechanical routing/securing functions simultaneously. This multi-functionality allows the system to achieve proper cable management without adding dedicated routing structures, thereby maintaining device simplicity and compactness.
3Reliability
If conventional soldering, bolting, or riveting processes are used to connect terminals to metal plates, then connection durability is improved, but manufacturing time and process complexity increase
Solution Approach 1:
Traditional mechanical connection methods (soldering, bolting, riveting) are replaced with a press-fit or snap-fit mechanical insertion system. The sensing unit is directly inserted into the busbar structure, eliminating the need for thermal or mechanical fastening processes while maintaining connection reliability.
4Measurement precision
If sensing units are distributed across multiple locations to monitor all battery cells, then measurement coverage is improved, but device complexity and assembly difficulty increase
Solution Approach 1:
Multiple sensing functions (voltage sensing and temperature sensing) are merged into a single integrated sensing unit. This unified sensing unit can monitor multiple battery cells through its connection to the busbar, eliminating the need for separate distributed sensing components while maintaining comprehensive monitoring coverage.
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
The solution provides a simple and durable connection structure for battery cells with effective temperature and voltage sensing, enhancing electrical safety and heat dissipation, while maintaining a compact design.
Implementation Method 1
a sensing unit disposed on the other outer surface of the cell frame and electrically connected to the busbar plates by wire bonding
Data Source
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AI summary
A cell module assembly according to the present disclosure includes a plurality of battery cells; a cell frame accommodating the plurality of battery cells; busbar plates disposed on one outer surface of the cell frame to electrically connect the plurality of battery cells; and a sensing unit disposed on the other outer surface of the cell frame and electrically connected to the busbar plates by wire bonding.