Battery Module Sensor Connector Height Reduction
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Solution Overview
Problem
The existing battery modules with sensor devices on the upper surface face increased height dimensions and hindered connector insertion and removal due to bent bus bars, which exacerbate the issue of space constraints.
Innovation Solution
The sensor device is positioned above the bus bars on the upper surface, with its connector placed between the bent portions of adjacent bus bars, and its lower surface is positioned lower than the bent portion's upper edge, allowing for reduced height while maintaining connector accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If the sensor device is disposed on the upper surface of the cell-stacked body, then the voltage detection function is improved, but the height dimension significantly increases
Solution Approach 1:
The connector is repositioned from a vertical arrangement (above the bus bar) to a horizontal arrangement (between bent portions in the stacking direction), utilizing the width dimension to resolve the height dimension conflict. This dimensional shift allows voltage detection functionality while reducing overall height.
2Strength
If the bus bar has a bent portion protruding upward to relieve stress, then the stress resistance is improved, but the insertion and removal of connector is hindered
Solution Approach 1:
The bus bar is segmented into multiple portions including bent portions and flat portions. The connector is specifically positioned to engage with the flat portion rather than the bent portion, allowing the bent portion to maintain stress relief function while the flat portion provides connector accessibility.
Solution Approach 2:
Different portions of the bus bar have different geometries optimized for different functions: bent portions for stress relief and flat portions for connector connection. This local differentiation resolves the conflict between stress resistance and connector accessibility.
3Difficulty of detecting and measuring
If the connector is positioned above the bus bar, then the voltage detection connection is improved, but the height dimension increases and connector accessibility is reduced
Solution Approach 1:
The connector is repositioned from a vertical arrangement (above the bus bar) to a horizontal arrangement (between bent portions in the stacking direction), utilizing the width dimension to resolve the height dimension conflict. This dimensional shift allows voltage detection functionality while reducing overall height.
Data Source
AI summary
A battery module includes: a cell-stacked body constituted by stacking a plurality of cells; a plurality of bus bars, each of which connects terminals of adjacent cells; and a sensor device configured to detect a voltage of each cell. The sensor device is disposed above the plurality of bus bars disposed on an upper surface of the cell-stacked body as viewed from a width direction perpendicular to a stacking direction and an up-down direction, and includes a connector having a connection portion in the width direction. Each of the bus bars has a bent portion protruding upward between the cells to be connected. The connector is disposed between the bent portions of adjacent bus bars in the stacking direction, and a lower surface of the connector is provided at a position lower than an upper portion of the bent portion in the up-down direction.