Battery Module Protection Circuit Integration

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Solution Overview

Problem

Conventional battery module assembly processes are inefficient due to independent assembly of protection circuit components, leading to physical space constraints, reduced productivity, and inadequate heat dissipation and noise shielding.

Innovation Solution

Modularization of protection circuit components onto a support plate to form a single unit component, which includes a battery management system, conductive members, relay, and hole sensor, with the support plate serving as both a structural and heat dissipation element, and electromagnetic shield.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If protection circuit components are assembled independently in conventional battery module assembly processes, then each component can be manufactured separately, but the assembly process becomes inefficient and productivity is reduced

Engineering Contradiction:

Improvemanufacturability of individual componentsVSAvoidassembly process efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent merges multiple protection circuit components (relays, sensors, circuit boards) into a single integrated protection circuit module that is pre-assembled and tested as one unit. This module is then installed into the battery module as a single component, eliminating the need for independent assembly of each protection component and significantly improving assembly efficiency and productivity.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If protection circuit components are assembled independently, then component flexibility is maintained, but physical space constraints occur in the battery module

Engineering Contradiction:

Improvecomponent assembly flexibilityVSAvoidphysical space in battery module

Core Design Contradiction:

Adaptability or versatilityVSArea of stationary object

Solution Approach 1:

By combining multiple protection circuit components into a single integrated module with a compact structure, the patent reduces the total physical space required in the battery module. The module consolidates relays, sensors, and circuit boards into one space-efficient unit, eliminating the space that would be required for separate mounting of each component.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of operation

If protection circuit components are assembled independently, then individual component control is possible, but heat dissipation and noise shielding become inadequate

Engineering Contradiction:

Improveindividual component controlVSAvoidheat dissipation capability

Core Design Contradiction:

Ease of operationVSTemperature

Solution Approach 1:

The integrated protection circuit module is designed with a unified thermal management structure that provides effective heat dissipation for all components within the module. The module housing and mounting structure are configured to facilitate heat removal, and the close integration of components allows for optimized thermal pathways that are more effective than separate component mounting arrangements.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent utilizes the close proximity of components within the integrated module to create effective electromagnetic shielding. The metal housing and structural elements of the module serve as Faraday cages that shield sensitive electronic components from electromagnetic interference, converting the potential harm of electromagnetic noise into a beneficial shielding effect.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach simplifies the assembly process, improves heat dissipation, and enhances electromagnetic shielding, resulting in increased efficiency and productivity while providing optimal driving conditions for battery modules.

Implementation Method 1

the support plate serving as both a structural and heat dissipation element

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

the support plate serving as both a structural and heat dissipation element, and electromagnetic shield

Methodology Applied

Scientific EffectElectromagnetic shielding: Faraday Cage

Data Source

PatentUS10027139B2Battery module

Publication Date: 2018.07.17 SAMSUNG SDI CO LTD

AI summary

A battery module is disclosed. In one aspect, the battery module includes a battery management system configured to control charge and discharge operations of a battery pack, and a conductor configured to form charge and discharge current paths of the battery pack. The battery module also includes a relay electrically connected to the conductor and configured to selectively block the charge and discharge current paths and a support plate supporting the battery management system, the conductor and the relay.