Battery Module Voltage Sensing Receptacle Structure
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Solution Overview
Problem
The existing battery module manufacturing process is complex due to the need for multiple members for mechanical fastening and electrical connection, which increases size and manufacturing costs, and poses risks of damaging electrode terminals during voltage sensing member installation, affecting productivity and safety.
Innovation Solution
A battery module design featuring a receptacle structure for voltage sensing members that are inserted into mounting parts on the upper and lower cases, allowing for simplified assembly, stable voltage detection, and easy replacement, while minimizing the number of required members and preventing electrode terminal damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If voltage sensors are connected to electrode terminals by welding, then electrical connection is achieved, but the electrode terminals may be damaged and manufacturing cost increases
Solution Approach 1:
The patent combines mechanical fastening and electrical connection functions into a single integrated structure. The voltage sensing member includes a receptacle that receives the electrode terminal connection part, where mechanical retention and electrical contact are achieved simultaneously through the same structural components, eliminating the need for separate welding operations
Solution Approach 2:
The electrode terminal connection part serves multiple functions: it provides mechanical support for the voltage sensing member, establishes electrical connection for voltage detection, and enables easy assembly and disassembly. This multi-functional design replaces the specialized welding process with a universal pressing connection mechanism
2Reliability
If multiple members are used for mechanical fastening and electrical connection, then stable connection is achieved, but the assembly process becomes complicated and manufacturing cost increases
Solution Approach 1:
The patent integrates mechanical fastening and electrical connection into a single unified structure. The voltage sensing member's receptacle and the electrode terminal connection part work together as one integrated assembly unit, eliminating the need for separate fastening members and reducing the total number of components
Solution Approach 2:
The electrode terminal connection part is designed to perform both mechanical support and electrical connection functions simultaneously. This multi-functional component replaces what would traditionally require multiple separate members, simplifying both the structure and the assembly process
3Reliability
If voltage sensors are pressed to maintain tight contact with electrode terminals, then electrical connection is maintained, but the electrode terminals may be damaged during installation
Solution Approach 1:
The receptacle structure is designed with appropriate clearance and compliance features that cushion the insertion process. The electrode terminal connection part can be pressed into the receptacle with controlled force, preventing excessive stress that would damage the electrode terminals while still ensuring reliable electrical contact
Solution Approach 2:
The design changes the connection mechanism from rigid pressing to a more compliant insertion process. The receptacle and electrode terminal connection part are designed with geometric features that allow for gradual engagement, distributing the insertion force over a longer distance and reducing peak stresses on the electrode terminals
Data Source
AI summary
Disclosed is a battery module including a battery cell stack including a structure in which a plurality of battery cells connected to each other in series and/or in parallel is stacked and each of the battery cells is stood on one side thereof, voltage sensing members provided with connecting terminals electrically connected to electrode terminal connection parts of the battery cells for detecting voltages of the battery cells, an upper case covering the end of one side of the battery cell stack and portions of upper and lower ends of the battery cell stack, the upper case being provided with mounting parts, into which the voltage sensing members are inserted and mounted, and a lower case coupled to the upper case while covering the end of the other side of the battery cell stack and portions of the upper and lower ends of the battery cell stack.