Cell Module Frame Resistance Sensing for Expansion Detection

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Solution Overview

Problem

Existing methods for monitoring cell expansion in electrical energy storage devices require accurate calibration and are not simple or cost-effective, particularly for detecting critical deformations in cell module frames due to energy storage cell aging.

Innovation Solution

A cell module with a metallic frame acting as a passive resistive extension sensor, connected to a measuring unit, which measures deformation-dependent electrical resistance to detect critical expansions and deformations, eliminating the need for additional sensors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If impedance measurement is used to monitor cell expansion, then cell expansion can be detected, but accurate calibration is required and the method is not simple or cost-effective

Engineering Contradiction:

Improvecell expansion detectionVSAvoidcalibration requirement

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent combines the cell module frame structure with the extension sensor function by integrating a strain gauge directly into the frame. The frame serves dual purposes: providing mechanical support and acting as the sensing element. This merging eliminates the need for separate sensors and complex calibration procedures, as the strain gauge is pre-integrated and calibrated during frame manufacturing.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cell module frame performs self-measurement of its own deformation through the integrated strain gauge. The frame's own structural changes during cell expansion are directly measured by the embedded sensor, eliminating the need for external monitoring systems and complex calibration procedures. The frame essentially monitors itself.

Inventive Principle:

Principle #25Self-service

2Measurement precision

If additional extension sensors are installed to monitor frame deformation, then deformation detection is achieved, but device complexity and cost increase

Engineering Contradiction:

Improvedeformation detectionVSAvoidsensor quantity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent merges the structural frame with the sensing function by integrating the strain gauge directly into the frame structure. This eliminates the need for additional separate sensors, reducing device complexity and cost while maintaining accurate deformation detection capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cell module frame serves multiple functions: it provides mechanical support, clamps the energy storage cells, and simultaneously acts as the sensing element for deformation detection through the integrated strain gauge. This multi-functionality eliminates the need for dedicated separate sensors.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Strength

If the cell module frame is designed for high mechanical strength, then frame destruction is prevented, but the frame may still deform beyond detection thresholds due to cell expansion

Engineering Contradiction:

Improveframe strengthVSAvoiddeformation monitoring

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The integrated strain gauge provides continuous feedback on frame deformation levels. This feedback mechanism allows the system to monitor the frame's structural integrity in real-time and detect when deformation exceeds safe thresholds, enabling timely intervention before catastrophic failure occurs, thus enhancing reliability while maintaining strength.

Inventive Principle:

Principle #23Feedback

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

Provides a simple, cost-effective method to monitor cell expansion and detect imminent frame destruction by measuring resistance changes in the metallic frame, ensuring timely detection and prevention of unsafe conditions.

Implementation Method 1

a passive resistive extension sensor having a deformation-dependent electrical resistance

Methodology Applied

Scientific EffectElectrical Resistance: Electrical Resistance

Implementation Method 2

extension sensor having a deformation-dependent electrical resistance

Methodology Applied

Scientific EffectPiezoresistive Effect: Piezoresistive Effect

Data Source

PatentUS12555837B2Cell module having a measuring device for detecting deformation and damage of a cell module frame

Publication Date: 2026.02.17 BAYERISCHE MOTOREN WERKE AG

AI summary

A cell module for an electrical energy storage device of a motor vehicle includes at least one cell structure made up of energy storage cells, a metallic cell module frame, enclosing the at least one cell structure, for clamping the energy storage cells, and a measuring device for detecting a deformation of the cell module frame related to cell expansion. The measuring device includes a passive resistive extension sensor having a deformation-dependent electrical resistance and a measuring unit connected to the extension sensor to output an electrical measurement signal characterizing the deformation-dependent electrical resistance of the extension sensor. The extension sensor is formed by the metallic cell module frame, with which the measuring unit is electrically contacted.