Battery Module Sensing Module Coupling Structure
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Solution Overview
Problem
Traditional battery modules require complex and costly processes for connecting multiple battery cells and sensing modules, leading to increased manufacturing costs and reduced structural stability against external forces.
Innovation Solution
A battery module design featuring cell cartridges with coupling protrusions and a sliding sensing module with guide ribs, allowing for simplified assembly and connection of multiple cartridges and sensing modules, with a voltage sensing terminal that elastically contacts the electrode terminal, and a bus bar for external connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a module case with a complicated support structure is used to fix battery cells, then structural stability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the support structure and coupling function into a single integrated module case design. The coupling protrusions are directly formed on the module case, eliminating the need for separate support structures and fastening components, thus reducing device complexity while maintaining structural stability.
Solution Approach 2:
The module case is designed to perform multiple functions: it provides structural support, enables mechanical coupling between modules through protrusions, and facilitates electrical connection. This multi-functionality reduces the number of separate components needed, simplifying the overall structure.
2Reliability
If separate processes are used for mechanical connection and electrical connection, then connection reliability is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent merges the mechanical coupling process and electrical connection process into a single simultaneous operation. When modules are coupled together using the protrusions and grooves, the electrode terminals are automatically aligned and connected, eliminating the need for separate mechanical assembly and electrical wiring steps.
Solution Approach 2:
The electrode terminals are pre-positioned and integrated with the module structure before final assembly. The coupling protrusions are designed to automatically align the terminals during the coupling process, so the electrical connection is established as part of the mechanical assembly rather than as a subsequent separate step.
3Ease of operation
If wire type connection is used for sensing module, then ease of assembly is improved, but product cost increases due to additional wire components
Solution Approach 1:
The patent extracts and eliminates the wire component from the sensing module connection. Instead of using separate wires to connect the sensing module to the electrode terminals, the design uses direct contact through the coupling structure, removing the need for additional wire components and reducing manufacturing cost.
4Strength
If welding type connection is used for sensing module, then connection strength is improved, but resistance to vibration impact deteriorates and manufacturing complexity increases
Solution Approach 1:
The patent replaces the welding process with a mechanical coupling system. The coupling protrusions and grooves provide a mechanical connection that is inherently more resistant to vibration and impact than welded joints, while also simplifying the manufacturing process by eliminating welding operations.
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
This design simplifies the manufacturing process, reduces costs, and enhances structural stability by enabling a straightforward connection of battery cells and sensing modules while maintaining stability under external impacts.
Implementation Method 1
a voltage sensing terminal that elastically contacts the electrode terminal
Data Source
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AI summary
A battery module according to an exemplary embodiment of the present disclosure includes a plurality of cell cartridges including at least one battery cell having an electrode terminal and a molding case to receive the battery cell, the molding case having a plurality of coupling protrusions protruding outward, and a sensing module connected to the coupling protrusions to couple the plurality of cell cartridges, the sensing module having a voltage sensing terminal coming into contact with the electrode terminal by the coupling. According to one aspect of the present disclosure, a cost and time taken to manufacture the battery module may reduce by simplifying a connection structure of the plurality of battery cells, and simplifying a coupling structure between the battery cell and the sensing module installed to sense the voltage of the battery cell.