Battery Module End Block Asymmetry for Odd Cell Count

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Solution Overview

Problem

Existing battery modules face challenges in efficiently utilizing space and ensuring safety, particularly when the number of battery cells is odd, leading to inconvenient terminal placement and longer connection wires.

Innovation Solution

The battery module incorporates end blocks with a protection device and insulating materials, positioning the protection device within the end blocks and using connection members for efficient terminal placement, allowing for diagonal electrode terminal positioning even with an odd number of cells, thus reducing wire length and enhancing spatial efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the number of battery cells is odd, then the terminal placement becomes inconvenient and wire length increases, but maintaining even number arrangement limits design flexibility

Engineering Contradiction:

Improveterminal placement convenienceVSAvoidconnection wire length

Core Design Contradiction:

Ease of operationVSLength of moving object

Solution Approach 1:

The patent introduces asymmetric end blocks with different structures: one end block contains a protection device while the other does not. This asymmetric design enables convenient terminal placement for odd-numbered battery cell arrangements, allowing electrode terminals to be positioned at diagonally opposite corners and reducing connection wire length compared to symmetric designs.

Inventive Principle:

Principle #4Asymmetry

2Reliability

If protection devices are not integrated into the end blocks, then the structure is simpler, but safety and spatial efficiency are compromised

Engineering Contradiction:

Improvebattery module safetyVSAvoidend block structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the protection device with the end block structure, integrating safety components directly into the structural elements. The protection device is positioned within the end block and electrically connected between battery cells, combining protective function with structural support while improving spatial efficiency.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The end block serves as an intermediary component that houses the protection device and provides electrical connection pathways. Connection members within the end block mediate the electrical connection between battery cells while the protection device monitors and protects the circuit.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Object-affected harmful factors

If insulating materials are used in end blocks, then safety is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveelectrical insulationVSAvoidend block manufacturing

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The end block is constructed as a composite structure combining insulating materials with conductive connection members. The insulating material forms the main body of the end block, while connection members are integrated within it, creating a composite component that provides both insulation and electrical connectivity in a single manufacturable unit.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS9837687B2Battery module

Publication Date: 2017.12.05 SAMSUNG SDI CO LTD

AI summary

A battery module includes a plurality of battery cells arranged in one direction, a pair of end plates at outsides of respective outermost battery cells among the plurality of battery cells, a pair of end blocks between the end plates and the respective outermost battery cells, and a protection device in at least one end block of the pair of end blocks.