Battery Module Voltage Sensing via Folded Terminal Surface Contact
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Solution Overview
Problem
Conventional battery modules face challenges with reliability of voltage measurement due to contact resistance changes and increased complexity in assembly, along with potential short circuits and moisture accumulation, especially in applications exposed to external forces and long-term use.
Innovation Solution
A battery module structure where electrode terminals are folded to form a bent connection part, surrounded by a voltage sensing member mounted in a surface contact manner, with an elastic connection part and insulative cap to ensure stable and moisture-resistant voltage measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional point contact voltage sensing is used, then the device complexity is reduced, but the measurement precision deteriorates due to contact resistance changes
Solution Approach 1:
The patent transitions from point contact (0D/1D) to surface contact (2D) between the voltage sensing member and electrode terminals. The sensing member's contact surface is designed to substantially coincide with the terminal surface, creating extensive surface contact that eliminates contact resistance issues while maintaining assembly simplicity through the folded terminal configuration.
2Reliability
If electrode terminals are left unfolded, then the ease of manufacture is improved, but the reliability deteriorates due to loose contact and potential short circuits
Solution Approach 1:
The electrode terminals are pre-folded to form bent connection parts before assembly into the battery module. This preliminary folding action creates tight contact between terminals and prepares the geometry for subsequent mounting of the voltage sensing member, ensuring reliable electrical connection while simplifying the overall assembly process.
Solution Approach 2:
The electrode terminals are folded into bent connection parts with curved geometries that enable tight contact between terminals. The curved configuration of the bent connection parts allows the voltage sensing member to be mounted securely, improving electrical connection reliability while maintaining ease of manufacture.
3Reliability
If the voltage sensing member is not surrounded by protective structure, then the device complexity is reduced, but the reliability deteriorates due to moisture accumulation and external force damage
Solution Approach 1:
The voltage sensing member and the bent connection part are integrated into a unified structure where the sensing member is surrounded by the bent connection part. This merging of components provides protective enclosure against moisture and external forces while maintaining structural simplicity and avoiding additional separate protective elements.
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 configuration enhances measurement reliability, simplifies manufacturing, and prevents moisture accumulation, providing a structurally stable battery module suitable for applications like electric vehicles and hybrid systems.
Implementation Method 1
a voltage sensing member mounted to the bent connection part
Data Source
AI summary
Disclosed herein is a battery module configured in a structure in which two or more battery cells, each of which has electrode terminals formed at one end or opposite ends thereof, are stacked in a state in which the battery cells are electrically connected to each other, wherein the electrode terminals of the battery cells are formed of plate-shaped conductive members, the electrode terminals of the battery cells are folded such that the electrode terminals are in tight contact with each other to form a bent connection part at an electrical connection region between the battery cells, and the bent connection part is surrounded by a voltage sensing member mounted to the bent connection part.