Battery Module Assembly with Separable Frames and Integrated Sensing
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Solution Overview
Problem
Middle- or large-sized battery modules face challenges with low mechanical strength, increased size due to complex assembly processes, and safety issues from overvoltage, overcurrent, and overheating, which complicate the integration of sensing units and electrical connections.
Innovation Solution
A battery module design featuring high-strength sheathing members and a compact assembly structure with separable frame members for vertical mounting, integrated sensing units for voltage and temperature monitoring, and simplified electrical connections using welding and bus bars, reducing the need for additional coupling members and enhancing structural stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If pouch-shaped battery cells are used to reduce weight and size, then weight to capacity ratio is improved, but mechanical strength deteriorates
Solution Approach 1:
The patent applies composite materials by combining the lightweight pouch-shaped battery cell structure with a rigid frame member and high-strength sheathing members. The frame member provides structural support while the pouch cells maintain their low weight, creating a composite system that achieves both lightweight design and mechanical strength.
2Stability of the object's composition
If complex assembly processes with multiple coupling members are used, then structural stability is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple functions into integrated components. The frame member simultaneously provides structural support, mounting positions for battery cells, and structural reinforcement. The sheathing members combine mechanical protection with electrical insulation functions, reducing the need for separate coupling members and simplifying assembly.
Solution Approach 2:
The frame member serves multiple functions: it provides the structural framework, mounts battery cells through integrated mounting positions, and reinforces overall structure. This multi-functionality eliminates the need for separate coupling members, reducing assembly complexity while maintaining structural stability.
3Reliability
If sensing units are integrated for safety monitoring, then reliability is improved, but device complexity increases
Solution Approach 1:
The sensing units are merged with the frame member structure. Temperature sensors and voltage sensors are integrated into the frame member, which also provides mechanical support and mounting functions. This integration allows safety monitoring capabilities to be added without requiring separate mounting structures or increasing overall assembly complexity.
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
The solution minimizes weight and size while reinforcing mechanical strength, simplifies assembly, prevents short circuits, and ensures efficient operation and safety, enabling the construction of compact, high-output battery systems for applications like electric vehicles.
Implementation Method 1
two or more unit modules each having one or more plate-shaped battery cells, as unit cells, surrounded by a high-strength sheathing member made of synthetic resin or metal
Implementation Method 2
simplified electrical connections using welding and bus bars
Data Source
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AI summary
Disclosed herein is a middle- or large-sized battery module including two or more unit modules each having one or more plate-shaped battery cells, as unit cells, surrounded by a high-strength sheathing member made of synthetic resin or metal, and separable upper and lower frame members coupled with each other in an assembly-type coupling structure such that the unit modules are vertically mounted in the upper and lower frame members. 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 middle- or large-sized 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.