Battery Module Layout With Direct Sensing for Flexible Pack Integration
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Solution Overview
Problem
Conventional battery modules have low space utilization and limited design flexibility due to the stacking of battery cells only in the thickness direction, leading to challenges in configuring battery packs for restricted spaces and increasing the risk of rapid fire propagation. Additionally, the complex connector structure for sensing electrical properties complicates manufacturing and increases costs.
Innovation Solution
The proposed battery module design connects battery cells in both the longitudinal and thickness directions, enhancing space utilization and design flexibility. This design includes a battery cell assembly with longitudinal unit cells, a module case, a sensing line connected to the electrode leads, and a sensing plate exposed outside the module case, allowing for direct sensing without complex connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If battery cells are stacked only in the thickness direction, then the structure is simple to manufacture, but space utilization is low and design flexibility is limited
Solution Approach 1:
The patent transitions from single-direction (thickness direction) stacking to multi-directional (thickness + longitudinal) arrangement of battery cells. This dimensional expansion allows cells to be organized in a three-dimensional configuration within the module, significantly improving space utilization while maintaining manufacturing feasibility through systematic arrangement patterns.
2Ease of manufacture
If battery cells are stacked only in the thickness direction, then the assembly process is simple, but design flexibility for restricted spaces is limited
Solution Approach 1:
The patent divides the battery module into multiple independent units (battery cell assemblies) that can be arranged in different configurations. Each unit consists of battery cells organized in specific patterns (e.g., series-parallel connections), allowing the overall module design to be adapted to various spatial constraints while maintaining standardized assembly processes for each unit.
3Measurement precision
If a complex connector structure is used for sensing electrical properties, then sensing accuracy is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent extracts the sensing function from the mechanical connector structure and implements it through separate sensing lines that are electrically connected to battery cell terminals. This separation allows the use of simple, standardized connectors for mechanical connection while independent sensing lines handle electrical property measurement, thereby maintaining sensing accuracy without requiring complex integrated connector designs.
4Reliability
If complex connectors and harnesses are used for sensing between modules, then electrical connection reliability is improved, but assembly complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the electrical connection function with the mechanical connection function by integrating sensing lines directly into the module structure during the assembly process. The sensing lines are routed through the module and connected to terminals in a way that combines structural support and electrical measurement functions, eliminating the need for separate complex harness assemblies and reducing overall assembly complexity while maintaining reliability.
Data Source
AI summary
The battery module according to the present disclosure includes: a battery cell assembly in which two or more longitudinal unit cells, each of which is composed of two or more battery cells having leads provided at both ends in the longitudinal direction and arranged in a row in the longitudinal direction, are stacked in a thickness direction of the battery cell; a module case in which the battery cell assembly is accommodated; a sensing line electrically connected to the electrode lead of a battery cell included in the battery cell assembly, and having one end exposed to an outside of the module case; and a sensing plate that is coupled to one end of the sensing line exposed to the outside.