Battery Module Voltage Sensing Assembly Without Bus Bar Welding
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Solution Overview
Problem
The existing battery module assembly structure for voltage sensing components, including bus bars, sensing members, and connectors, is prone to welding defects and is not robust enough, leading to high costs and vulnerability to impact or vibration.
Innovation Solution
A battery module design featuring a rigid printed circuit board with detachable sensing tips and a direct connector mechanically engaged with the board, eliminating the need for soldering and enhancing assembly ease and robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If laser welding is used to connect FPCB to bus bar, then electrical connection is achieved, but welding defects occur frequently and quality management becomes difficult
Solution Approach 1:
The patent replaces the laser welding process with a mechanical pressing connection system. The sensing tip is pressed onto the bus bar using a pressing device, eliminating the need for laser welding between FPCB and bus bar. This mechanical connection approach resolves the welding quality issues while simplifying the manufacturing process.
Solution Approach 2:
The patent extracts the sensing function from the FPCB structure and implements it through a separate sensing tip that mechanically connects to the bus bar. This separation allows the sensing tip to be independently optimized for mechanical connection rather than relying on welded connections.
2Adaptability or versatility
If FPCB is used for voltage sensing, then flexibility is achieved, but the component is vulnerable to impact and vibration
Solution Approach 1:
The patent segments the voltage sensing system into distinct components: a rigid bus bar, a sensing tip, and a pressing device. This segmentation allows each component to be optimized for its specific function, with the bus bar providing structural support and the sensing tip providing the electrical connection, thereby improving impact resistance.
3Reliability
If connector pin is soldered on FPCB, then electrical connection is achieved, but connector mounting becomes difficult and vulnerability to impact increases
Solution Approach 1:
The patent merges the electrical connection function and mechanical mounting function into a single integrated pressing connection system. The pressing device simultaneously establishes both the electrical connection and the mechanical mounting, eliminating the need for separate soldering and mounting processes.
Data Source
AI summary
A battery module according to the present disclosure includes: a cell stack including a plurality of battery cells that are stacked in one direction; and a sensing module located on a front portion or a rear portion of the cell stack for voltage sensing and electrical connection of the plurality of battery cells, wherein the sensing module includes: a main frame formed to cover a front surface or a rear surface of the cell stack and including a plurality of lead holes through which electrode leads of the plurality of battery cells are drawn out; a plurality of bus bars located on the main frame to be spaced apart from one another in one direction; and a printed circuit board formed of a rigid material, including a plurality of sensing tips detachably provided on corresponding bus bars, and attached to the main frame.