Battery Module with Integrated Protruding Connection Element
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Solution Overview
Problem
Conventional battery modules for electric vehicles require long, complex bus bars for interconnecting multiple modules, which occupy space, increase weight, and pose safety risks due to potential short circuits.
Innovation Solution
A compact battery module design with a box-shaped or prismatic housing featuring multiple parts, including lateral and end walls made of metallic materials, and a cover of synthetic material, allowing for efficient side-by-side arrangement and interconnection of modules with short, simple bus bars, reducing the risk of short circuits and minimizing space and weight requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional battery modules are arranged on a carrier structure, then the poles can be interconnected by bus bars, but long and complex bus bars are required which occupy space and increase weight
Solution Approach 1:
The invention divides the battery module into a housing and an integrated connection element that protrudes from the housing. This segmentation allows the connection element to serve dual purposes: providing structural support and enabling electrical connection, thereby eliminating the need for separate long bus bars and reducing overall weight.
Solution Approach 2:
The connection element is merged with the housing to form an integrated structure. The connection element protrudes from the housing and provides both mechanical support and electrical connection functions, combining what were previously separate components (housing and bus bar) into a single unified element.
2Reliability
If conventional battery modules are arranged on a carrier structure, then the poles can be interconnected by bus bars, but the bus bars have to be guided around the housing and have a complex geometrical structure
Solution Approach 1:
The connection element is integrated with the housing to form a unified structure, eliminating the need for separate complex bus bars that must be routed around the housing. The integrated design simplifies the overall geometry while maintaining reliable electrical connections.
Solution Approach 2:
Instead of having bus bars extend from external connections and be routed around the housing, the connection element protrudes directly from the housing in a simplified configuration. This inverted approach to connection architecture eliminates complex routing requirements.
3Productivity
If multiple battery modules are arranged side-by-side, then they can be interconnected, but conventional designs require long bus bars which occupy significant space
Solution Approach 1:
The modular design with protruding connection elements allows battery modules to be arranged side-by-side with direct connections between adjacent modules. This segmentation approach eliminates the need for long bus bars spanning across multiple modules, reducing the space required for interconnections and facilitating easier assembly.
Data Source
AI summary
A battery module includes a battery module housing, a plurality of battery cells accommodated in the battery module housing and electrically interconnected, a first connecting piece forming a first voltage polarity that is conductively connected to one of the battery cells, and a second connecting piece forming a second voltage polarity that is conductively connected to another one of the battery cells. The battery module housing includes a passage at each of at least three occupiable spots. The first connecting piece is arranged in one of the passages. The second connecting piece is arranged in another one of the passages.