Multi-Cell-Stack Battery Module Housing for High-Power Connection
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Solution Overview
Problem
Existing battery modules with single cell stacks face challenges in efficiently meeting high power demands due to increased manufacturing costs, weight, and complexity, particularly in implementing effective electrical connections between multiple cell stacks.
Innovation Solution
A battery module design featuring a plurality of cell stacks with insulating members and a module housing that allows for efficient electrical connections through bus bars and couplers, enabling simplified manufacturing and enhanced power delivery while maintaining structural stability and cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a single cell stack is used in the battery module, then the manufacturing cost and weight are reduced, but the electric power capacity is insufficient to meet high power demands
Solution Approach 1:
The battery module is divided into multiple cell stacks, each comprising multiple unit cells arranged in series. This segmentation allows the module to achieve high power capacity by combining multiple smaller stacks, while each stack maintains a manageable and standardized structure that simplifies manufacturing and assembly processes
Solution Approach 2:
The module housing is designed with receiving parts that can universally accommodate multiple cell stacks with standardized dimensions and configurations. This universal design allows the same housing structure to support different numbers and arrangements of cell stacks, providing flexibility in meeting various power requirements without redesigning the entire module
2Power
If multiple cell stacks are provided to increase electric power, then the power capacity is improved, but the manufacturing cost and weight increase
Solution Approach 1:
Multiple cell stacks are merged into a single integrated module housing with shared structural components, cooling systems, and electrical connection pathways. This combining approach allows the module to achieve high power capacity through multiple stacks while avoiding the weight penalty of duplicate support structures and systems for each individual stack
Solution Approach 2:
The module employs composite structural designs where the housing and support structures utilize materials optimized for both strength and weight efficiency. The integration of multiple cell stacks into a unified structure allows for optimized material distribution, using materials strategically where needed for structural integrity while minimizing overall weight
3Power
If multiple cell stacks are provided to increase electric power, then the power capacity is improved, but the manufacturing process becomes less efficient
Solution Approach 1:
The battery module is divided into multiple cell stacks, each comprising multiple unit cells arranged in series. This segmentation allows the module to achieve high power capacity by combining multiple smaller stacks, while each stack maintains a manageable and standardized structure that simplifies manufacturing and assembly processes
Solution Approach 2:
The module housing is designed with receiving parts that can universally accommodate multiple cell stacks with standardized dimensions and configurations. This universal design allows the same housing structure to support different numbers and arrangements of cell stacks, providing flexibility in meeting various power requirements without redesigning the entire module
4Power
If multiple cell stacks are provided to increase electric power, then the power capacity is improved, but the electrical connection implementation becomes more complex
Solution Approach 1:
Multiple cell stacks are merged into a single integrated module housing with shared structural components, cooling systems, and electrical connection pathways. This combining approach allows the module to achieve high power capacity through multiple stacks while avoiding the weight penalty of duplicate support structures and systems for each individual stack
Solution Approach 2:
The module housing serves as an intermediary structure that provides integrated receiving parts for multiple cell stacks and facilitates electrical connections between them. The housing includes built-in connection pathways and contact points that automatically establish electrical continuity when stacks are installed, eliminating the need for complex external wiring and connection mechanisms
Data Source
AI summary
A battery module includes a cell stack in which a plurality of unit cells including terminal parts are aligned in a first direction and an insulating member surrounds the plurality of unit cells; and a module housing in which a plurality of receiving parts, into each of which the cell stack is configured to be inserted, are provided and are aligned in a first direction and a second direction perpendicular to the first direction, wherein each of the plurality of receiving parts includes a fixing wall around the cell stack and having at least a portion which is in contact with the cell stack. The cell stacks adjacent to each other in the second direction are electrically connected to each other, and the cell stacks adjacent to each other in the first direction are electrically disconnected from each other, when not connected to an end module.