Compact Battery Module with Integrated BMS Sensing Housing
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Solution Overview
Problem
Existing secondary battery modules face challenges in achieving compactness and efficient coupling due to varying configurations and positions of cartridge assemblies and bus bars, leading to reduced energy density and poor welding quality.
Innovation Solution
A compact secondary battery module design integrates a master BMS with a sensing housing that can be selectively coupled with a cartridge assembly using hooks and grooves, and includes spare holes on the BMS circuit board for easy rework, facilitating detachment and attachment, and allowing for series/parallel scalability between modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a master BMS is provided between separate modules for balancing, then module management capability is improved, but the dimensional area increases and energy density deteriorates
Solution Approach 1:
The master BMS is merged with the cartridge assembly by integrating it into the sensing housing that couples with the cartridge. This consolidation eliminates the need for separate master BMS units between modules, reducing dimensional area while maintaining management capability through the integrated sensing and control system.
2Adaptability or versatility
If various configurations and positions of cartridge assembly and bus bar are used, then adaptability is improved, but coupling efficiency is reduced and welding quality deteriorates
Solution Approach 1:
The sensing housing is designed with a universal coupling structure featuring hooks and grooves that can accommodate different cartridge assembly configurations. This standardized interface maintains adaptability while ensuring consistent, precise positioning that enables high-quality welding through reliable alignment.
3Ease of manufacture
If unnecessary dimensional area is provided for welding process, then ease of manufacture is improved, but energy density deteriorates
Solution Approach 1:
The cartridge assembly and bus bar are pre-positioned with precise alignment features during assembly, eliminating the need for excessive dimensional tolerances or adjustment space during welding. This preliminary positioning ensures manufacturing ease while minimizing the dimensional area required, thereby preserving energy density.
Data Source
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AI summary
A compact secondary battery module integrated with BMS is disclosed, which includes a cartridge assembly stacked and coupled with at least two or more cartridges receiving a secondary battery cell therein; and a sensing housing disposed on a side surface of the cartridge assembly, in which two or more bus bars electrically connected with an electrode of a corresponding cell are disposed in a predetermined pattern, and a BMS circuit board that can be connected with each of the bus bars is prepared integrally.