Battery Module with Stacked Cells and Coupling Members

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Solution Overview

Problem

Conventional secondary battery modules face challenges in scalability, mechanical strength, and safety due to the use of pouch-shaped cells with low mechanical strength, complex electrical connections, and a rigid structure that complicates size adjustments and increases the risk of external impact damage.

Innovation Solution

A compact secondary battery module design featuring stacked unit cells with a separated case structure, high-strength safety members, and integrated circuit units for voltage, current, and temperature sensing, allowing for flexible capacity and output adjustments, enhanced mechanical safety, and stable electrical connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of stationary object

If pouch-shaped cells are used as unit cells, then the battery module becomes light and inexpensive, but the mechanical strength of the cell sheath is lower making it difficult to manufacture a structurally strong battery module

Engineering Contradiction:

Improvebattery module weightVSAvoidcell sheath mechanical strength

Core Design Contradiction:

Weight of stationary objectVSStrength

Solution Approach 1:

The patent uses a composite structure combining pouch-shaped cells with a rigid module case and coupling members. The pouch cells provide lightweight energy storage while the aluminum alloy case and steel coupling members provide structural strength, creating a composite system that achieves both light weight and high strength.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The battery module is segmented into multiple functional components: pouch-shaped unit cells for energy storage, a rigid module case for structural support, and coupling members for mechanical connection. This segmentation allows each component to be optimized for its specific function while working together as an integrated system.

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If cells are mounted in cartridges and stacked in a module case, then the battery module can be manufactured, but the size of the battery module is increased and the manufacturing process becomes complicated

Engineering Contradiction:

Improvebattery module manufacturabilityVSAvoidbattery module size

Core Design Contradiction:

Ease of manufactureVSVolume of stationary object

Solution Approach 1:

The patent merges the unit cells directly into the module case structure, eliminating the intermediate cartridge component. The coupling members integrate the cells with the case walls, creating a more compact and simplified manufacturing process that reduces both the number of parts and the overall module size.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If plate-shaped electrode terminals are connected using wires, plates, or bus bars by welding, then electrical connection is achieved, but the connecting process becomes very complicated and requires skilled techniques

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidelectrical connection process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent introduces coupling members as intermediary components that provide integrated mechanical and electrical connection between unit cells and the module case. These coupling members simplify the connection process by combining multiple functions into a single component, reducing the need for complex welding operations while maintaining reliable electrical connections.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Strength

If a rigid structure is used for the battery module, then structural strength is improved, but the design of the battery module becomes difficult to change depending upon electrical capacity and output

Engineering Contradiction:

Improvebattery module structural strengthVSAvoiddesign flexibility for capacity and output changes

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The battery module uses a segmented design where unit cells are independently mounted on the module case using coupling members. This modular approach allows the number of cells to be easily adjusted to change capacity and output while maintaining the rigid structural integrity of the aluminum alloy case, providing both strength and adaptability.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS8039145B2Secondary battery module with exposed unit cells and insulation between terminals

Publication Date: 2011.10.18 LG ENERGY SOLUTION LTD

AI summary

Disclosed herein is a high-output, large-capacity secondary battery module, having a plurality of unit cells electrically connected to each other, for charging and discharging electricity. A plurality of unit cells are stacked one on another and mounted on a plate, preferably, between an upper case and a lower case, which are separated from each other, circuit units are continuously mounted at the side surfaces of the module for sensing the voltage, the current, and the temperature of the battery, controlling the battery, and interrupting electricity when overcurrent is generated, whereby the secondary battery module is constructed in a compact structure, design of the battery module is easily changed depending upon electrical capacity and output, and components of the battery module are stably mounted.