Battery Module Sensor Retention via Bus Bar Carrier Cavity
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Solution Overview
Problem
Existing battery modules for electric vehicles are costly and require lengthy manufacturing processes for monitoring operating conditions like temperature and voltage, with a need for improved systems and methods for retention and communication between sensors and electrochemical cells.
Innovation Solution
A battery module design featuring a bus bar carrier with flexible fingers that include a cavity for a sensor, allowing communication between the sensor and electrochemical cells, and a lead wire passing through an opening to facilitate communication and retention of the sensor, while also holding down the electrochemical cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sensor retention methods are used in battery modules, then sensor monitoring capability is provided, but manufacturing complexity increases and production time lengthens
Solution Approach 1:
The patent combines the sensor retention function with the bus bar carrier structure by integrating a cavity directly into the carrier. This merging eliminates the need for separate retention mechanisms, reducing manufacturing complexity while maintaining reliable sensor monitoring capability through the integrated design.
Solution Approach 2:
The bus bar carrier is designed to serve multiple functions: electrical connection through bus bars, mechanical support for the battery module, and sensor retention through the integrated cavity. This multi-functionality reduces the overall component count and manufacturing steps while ensuring reliable sensor monitoring.
2Reliability
If separate retention features are added for sensors, then sensor retention is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The sensor retention function is merged into the bus bar carrier by forming a cavity as an integral part of the carrier structure. This eliminates the need for separate retention features while providing secure sensor retention through the integrated cavity design.
3Productivity
If traditional manufacturing processes are used for battery modules with sensors, then production is maintained, but production time and cost increase
Solution Approach 1:
The sensor cavity is pre-formed as an integral part of the bus bar carrier during carrier manufacturing. This preliminary action allows sensors to be directly installed in the cavity without requiring additional retention feature installation steps, reducing manufacturing time and improving production efficiency.
Solution Approach 2:
By merging the retention function into the carrier structure itself, the patent eliminates separate retention installation steps from the manufacturing process. This integration streamlines production, reducing both time and cost while maintaining proper sensor retention.
Data Source
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AI summary
The present disclosure a battery module having electrochemical cells and a bus bar carrier. The bus bar carrier includes a finger having a first surface, a second surface opposite to the first surface and configured to be disposed proximate to a first electrochemical cell of the plurality of electrochemical cells, a thickness extending between the first surface and the second surface, an opening extending through the first surface, through the thickness, and through the second surface, and a cavity disposed adjacent to the opening and exposed through the second surface of the finger. The battery module also includes a lead wire passing through the opening from the first surface of the finger to the second surface of the finger, and a sensor coupled to the lead wire to enable communication between the sensor and the first electrochemical cell, wherein the sensor is disposed in the cavity.