Battery Pack CMU Flexible Wiring for Shock-Tolerant Monitoring
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Solution Overview
Problem
Battery packs face challenges in maintaining stable coupling between battery modules and cell monitoring units (CMUs) under external pressure, such as vibration or shock, and suffer from inefficiencies in space usage due to assembly tolerances and the need for multiple CMUs to transmit information from adjacent modules.
Innovation Solution
The implementation of a battery pack design that uses flexible wires to electrically connect the CMU and battery modules, allowing for stable transmission of electrical signals even with assembly tolerances, and minimizing the number of CMUs required by using a flexible wire connection system that includes a circuit portion for signal processing and a binding terminal for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a board-to-board type connection is used between battery module and CMU, then assembly is simplified, but assembly defects occur due to assembly tolerances
Solution Approach 1:
The patent uses a flexible wire instead of a rigid board-to-board connection. The flexible wire can bend and adapt to assembly tolerances between the battery module and CMU, maintaining reliable electrical connection without requiring precise alignment. This resolves the contradiction by providing both ease of assembly (like board-to-board) and connection reliability (unlike rigid connections).
2Reliability
If multiple CMUs are used to monitor adjacent battery modules, then monitoring coverage is improved, but space efficiency deteriorates
Solution Approach 1:
The patent designs a single CMU that can monitor multiple adjacent battery modules through the flexible wire connection system. The CMU is positioned to receive electrical signals from multiple battery modules simultaneously, providing comprehensive monitoring coverage while occupying minimal space. This resolves the contradiction by making one CMU serve multiple functions of monitoring several modules.
3Stability of the object's composition
If rigid connection is used between battery module and CMU, then connection stability is improved, but damage occurs under external shock
Solution Approach 1:
The patent employs a flexible wire connection between the battery module and CMU. This flexible connection can absorb and dissipate external shocks and vibrations without transmitting damaging forces to the CMU or battery module, while maintaining stable electrical connection. The flexibility allows the connection to move with external forces rather than resisting them rigidly, preventing damage.
4Volume of moving object
If short wire length is used to improve space efficiency, then space usage is optimized, but assembly tolerance compensation is reduced
Solution Approach 1:
The flexible wire is designed with optimal length and flexibility to compensate for assembly tolerances while minimizing space occupation. The wire's flexibility allows it to bend and accommodate position variations between components, and its length is carefully selected to provide sufficient tolerance compensation without excessive space consumption. This resolves the contradiction by achieving both space efficiency and adaptability.
Data Source
AI summary
A battery pack of the present disclosure includes: a pack housing accommodating a battery module therein; a monitoring portion monitoring the battery module; and a connecting portion provided to transmit an electric signal between the monitoring portion and the battery module, wherein the monitoring portion includes: a circuit portion processing the electrical signal; and a flexible wire electrically connecting the connecting portion and the circuit portion.