Integrated Cell Connection Unit for Battery Module Heat Dissipation
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Solution Overview
Problem
Conventional battery modules face challenges in efficiently dissipating heat and monitoring cell voltage and temperature due to the use of monolithic busbars and separate wiring harnesses, which can lead to reduced packing density and increased risk of abnormal reactions and shortened battery life.
Innovation Solution
A cell connection unit that integrates a substrate with electrode terminals, an electronic unit, and a connector system using press-fit or pin connectors to electrically connect the terminals and the electronic unit, reducing the need for separate busbars and wiring harnesses, while also incorporating a venting system for gas discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate busbars and wiring harnesses are used for electrical connection and monitoring, then electrical connection reliability is improved, but device complexity and space requirements increase
Solution Approach 1:
The patent combines the busbar and wiring harness into an integrated cell connection unit. The busbar includes integrated circuit boards that directly connect to electrode terminals, eliminating the need for separate wiring harnesses. This merging reduces structural complexity while maintaining electrical connection reliability through direct integrated pathways.
Solution Approach 2:
The cell connection unit serves multiple functions simultaneously: it provides electrical connection between cells, monitors cell voltage and temperature, and manages heat dissipation. The integrated circuit boards on the busbar perform both current conduction and sensing functions, making the system more universal and reducing the number of separate components needed.
2Measurement precision
If separate wiring harnesses are used for cell monitoring, then measurement accuracy is improved, but packing density decreases
Solution Approach 1:
The monitoring components are merged into the busbar structure itself. Circuit boards are integrated directly onto the busbar, allowing voltage and temperature sensors to be positioned at exact measurement points without requiring separate wiring harnesses. This integration maintains measurement precision while maximizing packing density by eliminating redundant components.
Solution Approach 2:
The patent transitions from three-dimensional wiring harness routing to a two-dimensional integrated circuit board layout on the busbar surface. This dimensional change allows monitoring components to be placed directly at measurement points, improving measurement accuracy while minimizing space occupation and maintaining high packing density.
3Reliability
If monolithic busbars are used for electrical connection, then electrical conductivity is improved, but adaptability for electronic components decreases
Solution Approach 1:
The monolithic busbar is segmented into modular sections with integrated circuit boards at strategic locations. Each segment maintains electrical conductivity through direct metal connections while providing mounting surfaces and connection points for electronic components. This segmentation preserves the conductivity benefits of monolithic structures while adding adaptability for sensors and monitoring devices.
Solution Approach 2:
The busbar is designed to serve multiple functions: current conduction, voltage monitoring, temperature sensing, and mechanical support for electronic components. The integrated circuit boards provide universal interfaces for connecting various sensors and monitoring devices, making the system highly adaptable while maintaining the electrical conductivity of the original monolithic structure.
Data Source
AI summary
Provided is a cell connection unit for a battery module. The cell connection unit includes: a substrate accommodating electrode terminals of the battery module; an electronic unit; a connector connected to the electronic unit; and an electronic circuit electrically connecting at least one of the electrode terminals of the battery module to the electronic unit via the connector. The connector includes a fixed electrical connector and a plurality of fixation connectors.