Battery Module Assembly With Fitted Bus Bar Sensing and Heat Isolation
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Solution Overview
Problem
Conventional battery modules face challenges in space utilization, assembly complexity, manufacturing costs, and safety due to their complex structure and limited design flexibility, which restricts their application in various spaces and increases the risk of fire propagation.
Innovation Solution
The battery module design includes a stack of longitudinal unit cells connected in both the longitudinal and thickness directions, with a sensing integrated bus bar structure that simplifies the coupling of bus bars and sensing members using fitting coupling, and incorporates a heat propagation prevention plate to enhance safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a complex bus bar frame structure is used to accommodate bus bars and sensing members, then the structural integrity is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The bus bar frame is divided into a front bus bar frame and a rear bus bar frame that are positioned at opposite ends of the module case. This segmentation allows each frame to be independently designed and assembled, reducing overall complexity while maintaining structural integrity through the distributed support structure.
Solution Approach 2:
The bus bar frames serve multiple functions: they provide structural support for the battery cells, accommodate the bus bars for electrical connections, and integrate the sensing members for monitoring. This multi-functionality eliminates the need for separate components, reducing device complexity while maintaining strength.
2Measurement precision
If a complex assembly structure with sensing plate and laser welding is used, then the measurement precision is improved, but the ease of manufacture deteriorates
Solution Approach 1:
The sensing member is integrated with the bus bar to form a single unified component. This merging eliminates the need for separate sensing plate and connector assemblies, simplifying the assembly process while maintaining sensing precision through the direct electrical contact between the bus bar and sensing elements.
3Ease of manufacture
If battery cells are stacked only in thickness direction, then the manufacturing process is simplified, but the space utilization and design flexibility are reduced
Solution Approach 1:
The battery cells are arranged not only in the thickness direction but also extend in the longitudinal direction of the module. This dimensional expansion allows for more flexible space utilization and design configurations while maintaining a relatively simple stacking process within each directional plane.
4Productivity
If multiple battery cells are stacked in one module, then the productivity is improved, but the reliability deteriorates due to fire propagation risk
Solution Approach 1:
The module is divided into multiple independent battery cell stacks arranged in parallel. This segmentation creates physical and thermal isolation between individual cell groups, allowing high productivity through multiple cells per module while improving reliability by preventing fire propagation between stacks.
Data Source
AI summary
A battery module according to the present disclosure includes a battery cell assembly including two or more longitudinal unit cells, each of the two or more longitudinal unit cells including two or more battery cells arranged in a row in a longitudinal direction, wherein the battery cell includes a pair of electrode leads at both ends in the longitudinal direction, and each of the two or more longitudinal unit cells are stacked in two or more columns in a thickness direction of the battery cell; a bus bar coupled to each of the pair of the electrode leads of the battery cell included in the battery cell assembly and electrically connecting the battery cells; a sensing member coupled to the bus bar and sensing electrical characteristics of the battery cell; and a module case accommodating the battery cell assembly, the bus bar, and the sensing member, wherein the bus bar and the sensing member are coupled by fitting coupling in which one of the bus bar and the sensing member is fitted into and coupled to the other thereof.