Cylindrical Battery Module Housing Without Cable Harnesses
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Solution Overview
Problem
Existing battery modules for light electric vehicles face safety risks due to cable harnesses, which can lead to short circuits and safety-critical behavior, as battery cells cannot be switched off as voltage sources.
Innovation Solution
A battery module design that eliminates cable harnesses by using direct connections between cylindrical battery cells and a control unit or sensors integrated within, featuring a housing with receptacles for cell connectors and a control device, allowing for series and parallel electrical connections without cables, and incorporating a folded connection for secure assembly and easy integration into vehicles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cable harnesses are used to connect battery cells to control units, then electrical connections can be established, but the risk of short circuits increases and safety is compromised
Solution Approach 1:
The patent removes cable harnesses from the battery module design. Instead of using separate cables to connect battery cells to control units, the connections are integrated directly into the housing structure through recesses that receive battery cells, eliminating the intermediate cable component that poses short circuit risks.
Solution Approach 2:
The patent combines the housing structure with the electrical connection function. The housing elements are designed with recesses that simultaneously provide mechanical support and electrical connectivity, merging the structural and electrical functions into a single integrated component rather than separate cable harnesses.
2Ease of operation
If multiple cable harnesses are installed for connecting sensors and control units, then monitoring functions are enabled, but production complexity and safety risks increase
Solution Approach 1:
The patent eliminates cable harnesses from the system, removing the complex installation and connection process associated with routing and securing multiple cables while maintaining all necessary monitoring and control functions through integrated contacts.
Solution Approach 2:
The housing structure serves multiple functions simultaneously: it provides mechanical support for battery cells, establishes electrical connections, and enables monitoring functions. This multi-functionality eliminates the need for separate cable harnesses for each function, simplifying production.
3Reliability
If traditional cable-based connections are used, then electrical connectivity is achieved, but the risk of safety-critical behavior increases due to potential cable damage
Solution Approach 1:
The patent removes vulnerable cable harnesses from the battery module design, eliminating the source of potential cable damage and short circuits while maintaining reliable electrical connections through integrated contacts within the housing structure.
Solution Approach 2:
The patent designs the housing with integrated protective structures that prevent cable damage before it can occur. By eliminating exposed cables and using protected integrated contacts, the design preemptively prevents the harmful effect of cable damage that could lead to safety-critical behavior.
Data Source
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AI summary
The invention relates to a battery module comprising a plurality of cylindrical battery cells (2), in particular lithium-ion battery cells (20), and a first housing element (31) with a plurality of cylindrical first receiving means (41) in which a first plurality (21) of electrically series- and/or parallel-connected battery cells (2) are accommodated, and a second housing element (32) with a plurality of cylindrical second receiving means (42) in which a second plurality (22) of electrically series- and/or parallel connected battery cells (2) are accommodated, wherein the first housing element (31) has a first main body (51) on which the first receiving means (41) are arranged, and the second housing element (32) has a second main body (52) on which the second receiving means (42) are arranged, wherein the first main body (51) and the second main body (52) are connected to one another, forming a receiving space (6) in which a control unit (10) of the battery module (1) is accommodated.