Battery Module Bus Bar Layout With Flexible Sensing Assembly
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Solution Overview
Problem
Conventional battery modules require significant assembly time and manpower, increase weight and volume, and have poor heat dissipation due to rigid sensing module assemblies, which also lead to reduced energy efficiency and increased manufacturing costs.
Innovation Solution
A battery module design featuring bus bar assemblies on both sides of the battery stack with a flexible, thin, and thermally conductive sensing module assembly on one side, which supports the stack downward, includes a surface pressure pad and thermal conductive member for enhanced cooling and heat dissipation, and is made of materials with insulation and heat resistance properties to prevent electrical communication with the upper cover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid sensing module assembly is used, then structural stability is improved, but weight and volume increase, reducing energy efficiency
Solution Approach 1:
The patent applies this principle by replacing the traditional rigid sensing module assembly with a flexible sensing module assembly that uses thin film structures. The flexible assembly maintains necessary structural stability while significantly reducing weight and volume, thereby improving energy efficiency per unit weight and per unit volume of the battery module.
Solution Approach 2:
The patent changes the physical parameters of the sensing module assembly by transitioning from rigid materials to flexible materials with different mechanical properties. This parameter change allows the assembly to maintain structural stability while reducing weight and volume, resolving the contradiction between stability and weight.
2Stability of the object's composition
If a rigid sensing module assembly is used, then structural stability is improved, but heat dissipation performance deteriorates
Solution Approach 1:
The flexible sensing module assembly uses thin film structures that provide better thermal contact with the battery cells compared to rigid assemblies. This improves heat dissipation performance while maintaining structural stability through the flexible design.
Solution Approach 2:
The patent employs composite materials in the flexible sensing module assembly that combine electrical insulation properties with thermal conductivity. This allows the assembly to maintain structural stability while effectively dissipating heat from the battery cells.
3Manufacturing precision
If separate assembly processes are used for bus bars and sensing module, then manufacturing precision is improved, but assembly time and manpower increase
Solution Approach 1:
The patent merges the bus bar assembly and the sensing module assembly into a single integrated assembly process. The flexible sensing module assembly can be assembled together with the bus bars in one operation, eliminating separate assembly steps while maintaining manufacturing precision through the flexible design that accommodates positioning tolerances.
Solution Approach 2:
The flexible sensing module assembly serves multiple functions simultaneously - it provides sensing capabilities, thermal management, and electrical insulation, while also serving as a structural component. This multi-functionality allows it to be assembled with bus bars in a unified process, reducing assembly time and manpower.
4Ease of manufacture
If sensing module assembly is fastened on upper side only, then ease of manufacture is improved, but heat dissipation performance deteriorates
Solution Approach 1:
The flexible sensing module assembly can be easily fastened to the upper side of the battery stack while maintaining good thermal contact across the entire surface. The flexibility allows it to conform to the battery cell surfaces, improving heat dissipation without complicating the manufacturing process.
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 design minimizes volume, improves energy efficiency, enhances cooling efficiency, increases fixability, and reduces manufacturing costs while blocking electrical communication, achieving weight reduction and improved heat dissipation.
Implementation Method 1
A thermal conductive member may be filled between the battery stack and the sensing module assembly
Implementation Method 2
a cooling plate disposed on a lower side of the battery stack parallel to the stacking direction of the battery cells
Data Source
AI summary
A battery module which includes: a battery stack formed by stacking a plurality of battery cells respectively including electrode tabs on each other; bus bar assemblies located on both sides of the battery stack, from which the electrode tabs are drawn, to electrically connect the plurality of battery cells to each other through the plurality of electrode tabs; and a sensing module assembly disposed on one side of the battery stack, from which the electrode tab is not drawn out, to electrically connect the bus bar assemblies on both sides of the battery stack.