Bridged Battery Pack Sensing Module for Multi-Array Assembly
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Solution Overview
Problem
As electric vehicle battery packs experience increased cell counts, the need for multiple battery pack sensing modules arises, which can complicate design architecture and increase assembly challenges due to tolerance stack-up issues and stress on connectors.
Innovation Solution
A single larger battery pack sensing module is designed to bridge across two arrays or cell stacks, incorporating multiple battery monitoring integrated circuits and a robust internal array bridge bracket for alignment and support, reducing the number of interface connectors and relaxing tolerance requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple battery pack sensing modules are used to handle increased cell counts, then measurement coverage is improved, but device complexity and assembly difficulty increase
Solution Approach 1:
The patent combines multiple sensing functions into a single battery pack sensing module that can monitor multiple battery cell arrays. The module integrates multiple integrated circuits, flexible printed circuit boards, and sense lead connectors into one unified device, eliminating the need for separate sensing modules for each array and simplifying the overall system architecture.
Solution Approach 2:
The battery pack sensing module is designed with universal functionality to monitor multiple battery cell arrays simultaneously. The module incorporates multiple integrated circuits and sense lead connectors that can interface with different arrays, making it a multi-functional device that replaces several specialized sensing modules.
2Measurement precision
If multiple battery pack sensing modules are used, then measurement coverage is improved, but assembly precision requirements increase due to tolerance stack-up
Solution Approach 1:
By consolidating multiple sensing functions into a single module, the patent reduces the number of separate components that need to be assembled. This eliminates cumulative tolerance stack-up issues that would arise from assembling multiple independent sensing modules, as there is only one module whose dimensions and connector positions need to be controlled.
3Measurement precision
If multiple battery pack sensing modules are used, then measurement coverage is improved, but connector stress increases
Solution Approach 1:
The single sensing module design consolidates multiple connector interfaces into one unified structure. This distribution of connection points across a single module reduces the stress concentration that would occur with multiple separate modules, each requiring their own connector assemblies.
4Device complexity
If a single larger sensing module is used to bridge two arrays, then device complexity is reduced, but the module size increases
Solution Approach 1:
The patent employs a nested structure where multiple integrated circuits, flexible printed circuit boards, and sense lead connectors are integrated within a single housing. The flexible printed circuit boards are nested within the module structure, and the integrated circuits are mounted on rigid circuit boards that are themselves integrated into the overall module assembly, allowing compact packaging of the enlarged functional unit.
Data Source
AI summary
A battery pack sensing module includes a rigid printed circuit board that is to be carried by and bridge between a pair of battery cell arrays, a plurality of integrated circuits mounted on the rigid printed circuit board, and a pair of sense lead connectors at opposite ends of the rigid printed circuit board. Each of the sense lead connectors is electrically connected with at least one of the integrated circuits and can mate with a receiving connector of one of the battery cell arrays to establish an electrical connection between the receiving connector and the at least one of the integrated circuits.