Battery Module Controller Integration via Press-Fit Terminals
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Solution Overview
Problem
The existing battery pack technologies face challenges in increasing energy density due to the large volume occupied by cell module controllers, which are typically disposed outside the battery module and connected using wiring harnesses, leading to high installation risks and potential safety hazards.
Innovation Solution
The integration of the cell module controller within the battery module, utilizing a direct connection between the detecting terminal and the terminal connecting portion on the battery connecting strip, along with press-fit contacts, eliminates the need for wiring harnesses, reducing installation risks and enhancing safety by simplifying the connecting structure and shortening the distance between components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the cell module controller is disposed outside the battery module and connected through wiring harness, then the installation is simple and easy to implement, but the volume occupied is large, manual work dependency is high, installation efficiency is low, and the risk of mistakes and short circuits is high
Solution Approach 1:
The cell module controller is integrated inside the battery module, merging previously separate components (controller and battery module) into a single unified structure. This eliminates the need for external wiring harness connections and reduces the overall volume occupied, while maintaining ease of installation through standardized interfaces.
Solution Approach 2:
The wiring harness connection system is extracted and removed from the design. By eliminating the wiring harness entirely and using direct integration with terminal connecting portions, the patent removes the source of installation errors and short circuit risks while simplifying the connection structure.
2Ease of manufacture
If the cell module controller is disposed outside the battery module, then the connection is simple, but the space occupied in the battery pack is large, reducing the energy density
Solution Approach 1:
The cell module controller is merged with the battery module by placing it inside the module's housing space. This integration allows the controller to share the battery module's structural space, significantly reducing the overall volume occupied in the battery pack and thereby increasing energy density.
3Ease of operation
If the wiring harness connection is used to connect the cell module controller with the battery module, then the connection is easy to implement, but the installation efficiency is low and the risk of short circuit is high
Solution Approach 1:
The wiring harness is extracted and completely removed from the connection system. The patent replaces it with direct electrical connections through terminal connecting portions that are integrated into the battery module structure, eliminating the intermediate component that caused installation inefficiency and safety risks.
Solution Approach 2:
The terminal connecting portion serves as an intermediary structure that provides direct electrical connection between the battery cells and the cell module controller. This mediator eliminates the need for wiring harnesses while maintaining ease of connection through standardized terminal interfaces.
4Ease of manufacture
If the wiring harness is used for connection, then the installation is simple, but the danger level of battery in extreme situations is raised due to easy damage and short circuit
Solution Approach 1:
The wiring harness is extracted and removed from the system. By eliminating this vulnerable component that is prone to damage in extreme situations, the patent directly addresses the safety issue while maintaining connection functionality through integrated terminal structures that are more robust and protected.
Data Source
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AI summary
The present invention provides a battery module, including: a plurality of power batteries, a module casing, a separating plate, battery connecting strips, detecting terminals and a cell module controller; the power batteries are disposed in the module casing, the separating plate is arranged above the power batteries, and through-holes are arranged on the separating plate corresponding to electrode terminals of the power batteries, the battery connecting strips are arranged above the separating plate, and are connected with the electrode terminals of the power batteries through the through-holes, so that all the power batteries are electrically connected, the cell module controller is arranged above the separating plate, and press-fit holes are provided on the cell module controller, a terminal connecting portion is arranged on the battery connecting strip, the detecting terminal is located between the separating plate and the cell module controller, one end of the detecting terminal is connected with the terminal connecting portion, the other end of the detecting terminal is provided with a press-fit contact, the press-fit contact is connected in press-fit with the press-fit hole. The battery module provided by the present application reduces the risk in installation, and reduces the danger level of the battery in extreme situations.