Battery Module With Self-Coupling Cell Covers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery modules face challenges with low mechanical strength, increased size due to additional components, complex assembly processes, and potential for short circuits, which complicates manufacturing and operation, especially in compact and high-capacity applications like electric vehicles.
Innovation Solution
The use of high-strength cell covers with a symmetrically bent structure for easy coupling without additional members, integrated thermistors for temperature sensing, and a compact design that minimizes weight and size while ensuring structural stability and efficient heat dissipation through metal sheets with linear protrusions for coolant flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If additional coupling members are used to connect cell covers, then the mechanical strength and stability are improved, but the device complexity and assembly process become more complex
Solution Approach 1:
The coupling protrusions and coupling grooves are integrated directly into the cell cover structure itself, merging the coupling function with the cell cover body. This eliminates the need for separate coupling members while maintaining mechanical strength and stability.
Solution Approach 2:
The cell covers are designed to be self-coupling through the protrusion-groove mechanism, where the structure itself provides the coupling function without requiring external coupling members or complex assembly procedures.
2Strength
If more components are added to ensure structural stability, then the mechanical strength is improved, but the weight and size of the battery module increase
Solution Approach 1:
The coupling protrusions and grooves are integrated directly into the cell cover structure itself, merging the coupling function with the cell cover body. This eliminates the need for separate coupling members while maintaining mechanical strength and stability.
Solution Approach 2:
The cell cover serves multiple functions: it provides structural protection, thermal management interface, and self-coupling capability, eliminating the need for additional components that would increase weight and size.
3Measurement precision
If thermistors are integrated into the cell cover, then temperature sensing capability is improved, but the device complexity increases
Solution Approach 1:
The thermistors are integrated directly into the cell cover structure, merging the temperature sensing function with the cell cover body. This eliminates the need for separate sensing components and their associated mounting hardware.
Solution Approach 2:
The cell cover serves multiple functions: structural protection, thermal management interface, and temperature sensing, eliminating the need for additional components that would increase weight and size.
4Weight of moving object
If a compact design is implemented to reduce weight and size, then the weight to capacity ratio is improved, but the mechanical strength and structural stability deteriorate
Solution Approach 1:
The cell cover is made of metal material that provides high strength-to-weight ratio, enabling compact design while maintaining mechanical strength. The metal material offers both light weight and structural stability simultaneously.
Solution Approach 2:
The coupling protrusions and grooves are integrated directly into the cell cover structure itself, merging the coupling function with the cell cover body. This eliminates the need for separate coupling members while maintaining mechanical strength and stability.
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 solution enhances mechanical strength, simplifies assembly, reduces the risk of short circuits, and enables the production of compact, high-output, large-capacity battery systems suitable for electric vehicles by minimizing weight and size while ensuring efficient heat dissipation and operational safety.
Implementation Method 1
The sheathing member 140 is constructed in a laminate structure of a resin layer/a metal film layer/a resin layer
Implementation Method 2
linear protrusions for coolant flow
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
Disclosed herein is a battery module including two or more plate-shaped battery cells, as unit cells, constructed in a stacked structure in which electrode terminals of the battery cells are connected in series with each other and the electrode terminal connections are bent such that the battery cells are stacked, and a pair of high-strength cell covers for surrounding the outer surfaces of the battery cells when the cell covers are coupled with each other. The present invention has the effect of easily mounting a sensing unit that is capable of minimizing the weight and size of battery cells while effectively reinforcing the low mechanical strength of the battery cells and sensing the operation state of the battery cells to a battery module. In addition, the present invention has the effect of manufacturing the battery module by a simple assembly process without using a plurality of members for mechanical coupling and electrical connection, thereby decreasing the manufacturing costs of the battery module, and effectively preventing the battery module from being short-circuited or damaged during the manufacture or the operation of the battery module. Furthermore, the present invention has the effect of manufacturing a middle- or large-sized battery system having desired output and capacity using the battery module as a unit body.