Battery Module Multi-Direction Stacking for Space and Wiring Optimization
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Solution Overview
Problem
Battery modules for electric vehicles face challenges in achieving high density implementation within limited space due to the configuration of battery cells, conductive members, and voltage detection boards, which affects their manufacturability and efficiency.
Innovation Solution
The battery module design incorporates a unique arrangement of secondary battery cells stacked in multiple directions, using a combination of cases with dividers and bus bars to connect terminals, along with a wiring board and cover, to achieve a compact, cubic shape that allows for efficient space utilization and reduced wiring paths, enhancing manufacturability and vibration durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If battery cells are arranged in a conventional single-direction stacking manner, then the wiring path length is longer and installation space is larger, but the structural simplicity is easier to manufacture
Solution Approach 1:
The patent transitions from conventional single-direction stacking to three-dimensional multi-directional stacking, where battery cells are arranged in both longitudinal and lateral directions. This dimensional expansion enables shorter wiring paths and reduced installation space while maintaining manufacturability through standardized connection structures.
Solution Approach 2:
The patent implements nested positioning structures where dividing walls are embedded within the case structure, and battery cells are precisely positioned within defined compartments. This nesting approach enables compact multi-directional arrangement while maintaining manufacturing simplicity through integrated structural elements.
2Volume of moving object
If battery cells are densely packed to reduce installation space, then space utilization improves, but heat dissipation becomes more difficult
Solution Approach 1:
The patent introduces cooling channels as intermediary structures that flow through the battery module, providing thermal management pathways between densely packed cells. These channels serve as mediators that enable heat dissipation while maintaining high space utilization through integrated fluid flow paths.
Solution Approach 2:
The patent employs thin-walled case structures and dividing walls that provide structural containment while minimizing thermal resistance. These thin film structures allow efficient heat transfer from battery cells to cooling channels while maintaining compact packaging.
3Reliability
If conventional battery module structures are used, then manufacturing processes are simpler, but vibration durability is insufficient
Solution Approach 1:
The patent merges the case structure with dividing walls and positioning features into an integrated structural system. This consolidation enhances vibration durability by creating a rigid, unified structure that resists mechanical stress, while the modular design maintains manufacturing simplicity through standardized components.
Solution Approach 2:
The patent incorporates pre-designed positioning structures and pre-assembled submodules that ensure proper alignment and structural integrity before final assembly. This preliminary structuring enhances vibration resistance while simplifying the overall manufacturing process through modular construction.
Data Source
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AI summary
The battery module is characterized by comprising second battery cells (BT) each comprising a housing body (1a) including a bottom surface, a pair of main surfaces extending essentially orthogonal to the bottom surface from a pair of long sides of the bottom surface, and a pair of side surfaces extending between the main surfaces, and a lid member (1b) opposed to the bottom surface and having electrode terminals (PT, MT); a case (10, 20) in which the plurality of second battery cells are housed; a plurality of conductive members (BB) electrically connecting the electrode terminals (PT, MT) of the battery cells (BT); and a wiring board (30) placed at the upper portion of the conductive members (BB) on the case (10, 20), in that the plurality of secondary battery cells includes a first cell group including a plurality of secondary battery cells stacked along a first direction, and a second cell group including a plurality of secondary battery cells stacked along a second direction, the side surfaces of secondary battery cells of the first cell group are opposed to the main surfaces of the secondary battery cells of the second cell group, and the first cell group and the second cell group are connected in series.