Vehicle Battery Module Electrode Stacking With Stepped Cartridge Support
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Solution Overview
Problem
Conventional battery packs for vehicles face issues with limited stacking space, weight, and safety due to reinforcement for crash protection, which affects travel distance and performance.
Innovation Solution
A battery module design featuring a stepped portion in the main cartridge for electrode connection, supported by a sub-cartridge and ribs to prevent damage, allowing safe bending and stacking of electrodes, with a sensing board for integration and temperature/voltage monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery pack is reinforced with a reinforcing member that connects left, right and underside structures to comply with crash safety regulations, then crash safety is improved, but the battery stacking space becomes narrow and the weight increases
Solution Approach 1:
The battery pack is divided into multiple battery modules, each containing a specific number of battery cells arranged in series. This segmentation allows the reinforcing members to be optimized for each module while maintaining overall crash safety, and enables more flexible stacking arrangements that improve space utilization.
Solution Approach 2:
The patent transitions from traditional horizontal stacking to vertical stacking of battery modules. By changing the stacking dimension, the design achieves better space utilization within the constrained volume defined by crash safety requirements, allowing more battery cells to be packed into the available space.
2Reliability
If the battery pack is reinforced with a reinforcing member that connects left, right and underside structures to comply with crash safety regulations, then crash safety is improved, but the weight increases
Solution Approach 1:
The reinforcing members are constructed using composite materials that provide high strength-to-weight ratio. This allows the crash safety requirements to be met while minimizing the additional weight introduced by the reinforcing structure.
Solution Approach 2:
The reinforcing members are designed to serve multiple functions: providing crash safety reinforcement, supporting battery module stacking, and facilitating thermal management. This multi-functionality reduces the need for separate structural components, thereby reducing overall weight.
3Quantity of substance
If hundreds or thousands of battery cells are packed to meet desired power and capacity needs, then power and capacity are improved, but the complexity of assembly and management increases
Solution Approach 1:
The battery pack is segmented into multiple modules, each containing a manageable number of battery cells connected in series. This modular approach simplifies assembly by allowing standardized modules to be replicated and stacked, rather than individually assembling hundreds or thousands of cells.
Solution Approach 2:
Battery modules are designed with nested structures where smaller components are integrated into larger assemblies. The cartridge structure nests multiple battery cells in an organized manner, facilitating systematic assembly and reducing 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
Enhances electrode connection safety, simplifies bending processes, improves stacking efficiency, and ensures reliable operation with temperature and voltage monitoring, thereby improving battery pack performance and safety.
Implementation Method 1
when the positive electrodes and the negative electrodes of the first and second battery cells are bent in the stacking direction to be connected to each other
Implementation Method 2
welded to a sensing board provided with a busbar
Data Source
AI summary
An embodiment battery module for a vehicle includes first and second battery cells each having a planar shape, each battery cell being extended in one direction and including a positive electrode and a negative electrode separated from each other in a widthwise direction of the battery cells, and a main cartridge including an insertion space in which the battery cells are slidably inserted with the electrodes arranged alternately in a stacking direction and protruding outwards, wherein a stepped portion is provided in an inward end portion of the insertion space, inner surfaces of the stepped portion that are in contact with each end portion of the battery cells are spaced apart from each other in a sliding direction of the battery cells, and the end portions of the electrodes are in contact and overlap with each other when the electrodes are bent in the stacking direction to be connected to each other.