Battery Module Housing With Integrated Cell Stack Connections
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Solution Overview
Problem
Existing battery modules with multiple cell stacks face challenges in simplifying constituent components, reducing manufacturing costs and weight, and efficiently implementing electrical connections between cell stacks.
Innovation Solution
A battery module design featuring a cell stack with aligned unit cells and an insulating member, housed in a module with receiving parts that allow for efficient electrical connections between adjacent cell stacks, and includes bus bars for connecting unit cells and stacks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple cell stacks are provided to increase electric power capacity, then the amount of electric power is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the electrical connection function into the module housing structure itself. The housing includes conductive portions that directly connect adjacent cell stacks, eliminating the need for separate connection components. This integration reduces device complexity while maintaining the ability to provide high electric power capacity through multiple cell stacks.
Solution Approach 2:
The module housing serves multiple functions: it provides structural support, electrical insulation between non-adjacent stacks, and direct electrical connection between adjacent stacks through its conductive portions. This multi-functionality reduces the number of separate components needed, simplifying the overall device complexity while supporting high power capacity.
2Power
If multiple cell stacks are provided to increase electric power capacity, then the amount of electric power is improved, but the manufacturing cost increases
Solution Approach 1:
The electrical connection function is merged into the module housing structure, which is manufactured as a single component. This eliminates the need for separate connection components and reduces assembly steps, thereby lowering manufacturing cost while enabling high electric power capacity through multiple cell stacks.
Solution Approach 2:
The module housing performs multiple functions including structural support, insulation, and electrical connection. This multi-functionality reduces the total number of components that need to be manufactured and assembled, simplifying the manufacturing process and reducing costs while supporting high power capacity requirements.
3Power
If multiple cell stacks are provided to increase electric power capacity, then the amount of electric power is improved, but the weight of the module increases
Solution Approach 1:
The electrical connection structure is merged into the module housing itself, eliminating the need for separate connection components that would add weight. The housing material serves dual purposes as both structural element and electrical conductor, reducing overall module weight while maintaining high electric power capacity through multiple cell stacks.
4Productivity
If complex electrical connections are implemented between cell stacks, then the electrical connection efficiency is improved, but the device complexity increases
Solution Approach 1:
The electrical connection function is merged into the module housing structure. The housing includes conductive portions that directly connect adjacent cell stacks, providing efficient electrical connection through a simple, integrated structure rather than complex separate connection components.
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.