Battery Module Layout With Direct Sensing Pins and Flexible Cell Stacking

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Solution Overview

Problem

Conventional battery modules have limited space utilization and design flexibility due to stacked battery cells in only the thickness direction, and they require complex connectors and assembly structures for sensing electrical characteristics, which increases manufacturing costs and risks of fire propagation.

Innovation Solution

The battery module design includes longitudinal unit cells stacked in both the longitudinal and thickness directions, with a sensing line connected to electrode leads and a module case that allows direct sensing through external sensing pins, eliminating the need for complex connectors and simplifying assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If battery cells are stacked only in the thickness direction, then the module structure is simple, but space utilization and design flexibility are reduced

Engineering Contradiction:

Improvemodule structure simplicityVSAvoidspace utilization and design flexibility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent transitions from stacking battery cells only in the thickness direction (single dimension) to stacking in both thickness and longitudinal directions (multiple dimensions). This dimensional expansion enables the battery module to achieve better space utilization and design flexibility while maintaining manufacturing simplicity through standardized stacking processes.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Measurement precision

If connectors with male and female coupling structures are used for sensing, then electrical characteristics can be sensed, but the structure becomes complex and manufacturing costs increase

Engineering Contradiction:

Improveelectrical characteristic sensing capabilityVSAvoidconnector structure complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent extracts the sensing function from the power connection system by providing dedicated sensing lines that are separate from the main power connectors. These sensing lines extend directly from the battery cell terminals to the module terminal, enabling electrical characteristic sensing without requiring complex male-female coupling structures.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The module terminal is designed to serve multiple functions: it acts as both a power connection terminal and a sensing terminal. The sensing lines share the same terminal interface with the power connections, eliminating the need for separate complex sensing connectors and reducing overall device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Measurement precision

If complex connectors and assembly structures are used for sensing, then electrical characteristics can be measured, but manufacturing costs increase

Engineering Contradiction:

Improveelectrical characteristic sensing capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent merges the sensing function with the existing module terminal structure. The sensing lines are integrated into the same terminal interface used for power connections, and the terminal itself serves dual purposes. This consolidation eliminates the need for separate sensing connectors and reduces manufacturing steps, thereby lowering production costs.

Inventive Principle:

Principle #5Merging (Combining)

4Quantity of substance

If many battery cells are stacked in one module, then energy density increases, but fire propagation risk increases

Engineering Contradiction:

Improvebattery cell quantity and energy densityVSAvoidfire propagation risk

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The patent segments the battery module into multiple independent stacking directions (thickness direction and longitudinal direction) with battery cells arranged in series connections. This segmentation creates natural fire barriers between cell groups, as flames would need to propagate through multiple directions and barriers, significantly reducing fire propagation risk while maintaining high energy density through increased cell quantity.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20240258661A1Battery Module and Battery Pack Comprising Same

Publication Date: 2024.08.01 LG ENERGY SOLUTION LTD

AI summary

A battery module according to the present technology includes a battery cell assembly, a sensing line, and a module case. The battery cell assembly includes two or more longitudinal unit cells stacked in two or more columns in the thickness direction of the battery cell. Each of the longitudinal unit cells includes two or more battery cells arranged in a row in the longitudinal direction, where each of the battery cells has electrode leads at both opposing ends in the longitudinal direction. The sensing line is electrically connected to an electrode lead of the battery cell included in the battery cell assembly, and the module case is configured to surround and accommodate the battery cell assembly. Additionally, a sensing pin drawn out to the outside of the module case is provided on an end portion of the sensing line.