Battery Module Sampling Contact Structure for Expansion Reliability
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Solution Overview
Problem
Current battery module assembly processes are complex and prone to reliability issues due to the use of wire harnesses, which are susceptible to breakage during expansion of the battery module.
Innovation Solution
A battery module design that eliminates the need for wire harnesses by using a sampling connecting member with a fixing portion and contact portion, allowing for a secure and flexible connection between the electrical connecting piece and the circuit board, enabling the module to expand without breaking the sampling point.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire harness is used for sampling and transmitting information, then the sampling function can be achieved, but the assembly process becomes complicated and the reliability deteriorates due to multiple transmission passages and fixed structures
Solution Approach 1:
The patent extracts and eliminates the wire harness from the battery module, removing the complex transmission passages through electrode terminals, sheaths, and buckles. The sampling function is achieved directly through the battery shell with integrated sampling holes and conductive structures, significantly simplifying the overall structure while improving reliability by eliminating multiple potential failure points.
Solution Approach 2:
The patent merges the sampling function directly into the battery shell structure by integrating sampling holes and conductive paths within the shell itself. This consolidation eliminates the need for separate wire harnesses and multiple connection components, reducing structural complexity and improving reliability by creating a more integrated and robust sampling system.
2Reliability
If wire harness is arranged and fixed with electrical connecting pieces, then the sampling connection can be established, but the assembly time increases and the risk of wire harness breakage increases
Solution Approach 1:
The patent removes the wire harness entirely from the system, eliminating the time-consuming processes of arranging, positioning, and securing wire harnesses with buckles and sheaths. The sampling connection is established directly through the battery shell structure, dramatically reducing assembly time while eliminating the inherent breakage risks of wire harness connections.
Solution Approach 2:
The battery shell structure provides its own sampling functionality through integrated sampling holes and conductive paths. The shell itself serves as both the protective enclosure and the sampling conduit, eliminating the need for separate wire harness assembly operations and reducing dependency on additional components that require manual installation and securing.
3Reliability
If wire harness is fixed with electrical connecting pieces, then the sampling function can be maintained, but the sampling point becomes susceptible to fracture during battery module expansion
Solution Approach 1:
The patent eliminates the wire harness and its fixed connection points from the battery module. By removing these rigid, fixed-structure connections, the system gains the ability to accommodate battery module expansion without creating stress concentration points that would lead to fracture. The sampling function is maintained through the flexible, integrated shell structure that can accommodate dimensional changes.
Solution Approach 2:
The patent transitions from static, fixed wire harness connections to a dynamic system where the sampling structure is integrated into the battery shell that can expand and contract with the module. This dynamic integration allows the sampling points to move and adapt with the battery expansion, preventing fracture while maintaining reliable electrical connection throughout the module lifecycle.
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
Simplifies the assembly process, enhances reliability by allowing the sampling connecting member to adjust with the battery module expansion, and reduces the risk of damage from external impacts, ensuring stable sampling even during vibration.
Implementation Method 1
the contact portion pressing against the electrical connecting piece and keeping in contact with the electrical connecting piece
Data Source
Figure 1
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Figure 4~5
AI summary
The present application provides a battery module, which includes a plurality of batteries (1), an electrical connecting piece (2), a circuit board (3) and a sampling connecting member (4). The plurality of batteries (1) are arranged in a longitudinal direction (L); the electrical connecting piece (2) is electrically connected to the corresponding battery (1); the circuit board (3) is located above the corresponding battery (1) in a height direction (H); the sampling connecting member (4) is connected to the electrical connecting piece (2) and the circuit board (3); the sampling connecting member (4) includes a fixing portion (41) and a contact portion (42), the fixing portion (41) being fixed on the circuit board (3), the contact portion (42) being connected to the fixing portion (41), and the contact portion (42) pressing against the electrical connecting piece (2) and keeping in contact with the electrical connecting piece (2). By means of a sampling structure constituted by the connection between the sampling connecting member (4) and the electrical connecting piece (2) and between the sampling connecting member (4) and the circuit board (3), the connecting portion (42) of the sampling connecting member (4) and the electrical connecting piece (2) are in non-fixed contact in a press-against manner, and a sampling point is formed between the contact portion (42) and the electrical connecting piece (2).