Battery Module Assembly With Integrated Sensing and Serviceable BMS
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Solution Overview
Problem
Existing battery module assemblies face challenges in manufacturing due to increased battery cell thickness, requiring new high-strength exterior members and vertically separated assembly fastening structures, which limit the installation of a Battery Management System (BMS) and impose restrictions on the orientation of mounting parts, hindering efficient sensing and control.
Innovation Solution
A battery module assembly design where unit modules are stacked with cartridge assemblies having a greater thickness than the battery cells, featuring cell tabs bent in specific directions to secure insulating distances, and an adapter is used between cartridge assemblies to facilitate BMS installation, allowing for improved sensing and control by eliminating the need for additional partitions and enabling perpendicular mounting of support structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the thickness of battery cells is increased, then the energy storage capacity is improved, but new high-strength exterior members and vertically separated assembly fastening structures are required, increasing device complexity
Solution Approach 1:
The patent combines the exterior member and fastening structure into an integrated cartridge assembly that surrounds multiple battery cells. The cartridge assembly includes a body portion with front and rear covers that are coupled to surround the battery cells, eliminating the need for separate exterior members and vertically separated fastening structures. This merging approach maintains structural strength for thick battery cells while reducing overall assembly complexity.
2Ease of operation
If the BMS is provided on the rear of the lower case, then the sensing and control function is achieved, but it becomes impossible to perform BMS A/S (after-sales service)
Solution Approach 1:
The patent segments the BMS from the lower case by mounting it on the rear cover of the cartridge assembly, which is a separable component. The rear cover can be detached from the cartridge assembly body, allowing the BMS to be accessed and serviced independently. This segmentation enables both sensing/control functionality and ease of repair by allowing technicians to remove and replace the BMS without disassembling the entire battery module.
3Object-affected harmful factors
If cell tabs are bent in the front region to secure insulating distance, then insulating performance is improved, but additional partitions are needed in the rear region where tabs face each other
Solution Approach 1:
The patent applies different tab configurations to different regions of the battery cell assembly. In the front region, cell tabs are bent in the same direction to maintain insulating distance. In the rear region, tabs are configured to face each other with adequate spacing. This local quality approach allows the cartridge assembly to optimize insulating performance in each region without requiring additional partitions, as the cartridge body itself provides the necessary structural separation.
4Device complexity
If mounting parts are arranged in a linear structure, then the structural simplicity is maintained, but the battery module must be perpendicular to the sensing structure, limiting adaptability
Solution Approach 1:
The cartridge assembly is designed as a universal mounting structure that can accommodate battery cells in various orientations. The cartridge assembly with its front and rear covers can be arranged in different configurations (stacked, parallel, or perpendicular) to suit different battery module designs. The sensing structure is integrated into the cartridge assembly, allowing it to function in multiple orientations without requiring specific perpendicular alignment, thus providing both structural simplicity and mounting versatility.
Data Source
AI summary
Provided is a battery module assembly in which unit modules are stacked. Each of the unit modules includes: a plurality of battery cells; and a plurality of cartridge assemblies for respectively fixing the plurality of battery cells. The battery module assembly includes: a sensing assembly mounted to upper ends of the plurality of cartridge assemblies and assembled thereto; a front cover for covering front surfaces of the cartridge assemblies; and a connector coupled and fixed to the front cover. The connector includes: a connector body; and a first protrusion region that protrudes from the connector body. An upper sensing assembly connection hole is formed in an upper region of each of the cartridge assemblies.