Battery Module PCB Sensing Layout for Simpler Cell Connections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional secondary battery modules have complex structures that lead to increased manufacturing time and cost, reduced energy density, and require additional connecting members and processes like soldering, which occupy volume and increase manufacturing time.
Innovation Solution
A battery module design featuring a PCB assembly with integrated sensing patterns and a connection portion that simplifies the structure by overlapping with battery cells, eliminating the need for separate connection lines and harnesses, and using a wire connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If additional connecting members such as harnesses and connecting lines are used to connect sensing devices to battery cells, then the sensing function is achieved, but the manufacturing cost increases and the device complexity increases
Solution Approach 1:
The patent integrates the sensing device directly into the PCB assembly that is already part of the battery module structure. The PCB serves dual purposes: as a structural component for electrical connections and as a mounting platform for sensing devices (voltage, current, temperature sensors). This merging eliminates the need for separate harnesses and connecting lines, thereby reducing device complexity while maintaining sensing functionality.
Solution Approach 2:
The PCB assembly is designed to perform multiple functions simultaneously: electrical connection between battery cells, mechanical support structure, and sensing device platform. By making the PCB multi-functional, the patent eliminates the need for separate dedicated components for each function, reducing overall device complexity and manufacturing cost.
2Reliability
If soldering processes are performed for connection of connecting lines, then electrical connection is achieved, but the manufacturing time increases
Solution Approach 1:
The patent extracts and eliminates the soldering process from the manufacturing workflow by using alternative connection methods. The PCB assembly employs mechanical connection structures such as spring contacts, push-connectors, or conductive adhesives that enable electrical connections without requiring time-consuming soldering operations, thereby improving manufacturing productivity while maintaining reliable electrical connections.
Solution Approach 2:
The patent replaces the thermal-mechanical soldering process with a purely mechanical connection system. The PCB incorporates mechanical connection elements that physically engage with battery cell terminals to establish electrical connections, substituting the complex thermal process of soldering with a simpler mechanical assembly operation that is faster and more suitable for automated manufacturing.
3Reliability
If connecting lines are used for electrical connection, then the electrical connection is achieved, but the volume of the battery module increases
Solution Approach 1:
The patent merges the electrical connection function with the existing PCB structure. Instead of adding separate connecting lines that would occupy additional space, the PCB itself is designed with integrated conductive paths and connection terminals that directly establish electrical connections between battery cells, eliminating the volume occupied by external connecting lines while maintaining reliable electrical connectivity.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Disclosed are a battery module having an improved structure and a battery pack including the same, and more particularly a battery module having an improved structure, the battery module including a plurality of cylindrical battery cells, a module case accommodating the plurality of cylindrical battery cells, a PCB assembly disposed above the plurality of cylindrical battery cells, and a connection portion configured to electrically connect the plurality of cylindrical battery cells and the PCB assembly to each other, wherein the PCB assembly includes a PCB body plate and a first sensing pattern portion provided on one surface of the PCB body plate, and a battery pack including the same.