Integrated Power Switching Module for Hexahedral Battery Stacks
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Solution Overview
Problem
The complexity of assembling and the increased size of power switching modules for large-sized battery modules, which require multiple mechanical and electrical connections, pose challenges for compact integration and structural stability, especially in limited spaces like vehicles.
Innovation Solution
A power switching module with a compact arrangement structure for a hexahedral battery module assembly, featuring an insulative substrate with control elements and connection members mounted on it, simplifying electrical connections, reducing internal resistance, and enhancing structural stability by fixing the module's edges with a frame member and using hermetically sealing members for coolant flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple mechanical coupling and electrical connection members are used to construct a large-sized battery module, then the electrical connection and mechanical stability are improved, but the assembly process becomes very complicated and the total size of the system increases
Solution Approach 1:
The patent combines multiple separate connection members into a single integrated power switching module. The module integrates electrical connection terminals, mechanical coupling structures, and control elements into one unified component that attaches to the battery module, eliminating the need for separate mechanical and electrical connection operations.
Solution Approach 2:
The power switching module serves multiple functions simultaneously: it provides electrical connection for current withdrawal, mechanical coupling for structural stability, control functions for voltage and current management, and integration for space optimization. This multi-functional design reduces the number of separate components needed.
2Reliability
If multiple mechanical coupling and electrical connection members are used to construct a large-sized battery module, then the electrical connection and mechanical stability are improved, but the total size of the system increases
Solution Approach 1:
The patent combines multiple separate connection members into a single integrated power switching module. The module integrates electrical connection terminals, mechanical coupling structures, and control elements into one unified component that attaches to the battery module, eliminating the need for separate mechanical and electrical connection operations.
Solution Approach 2:
The power switching module is designed to attach to the surface of the battery module in a coupled manner, utilizing the available surface area rather than requiring additional linear space. This dimensional approach allows integration without significantly increasing the overall system volume.
3Adaptability or versatility
If the power switching module is constructed with multiple control elements for withdrawing electricity, then the electrical control capability is improved, but the structure becomes very complicated and difficult to assemble
Solution Approach 1:
The patent combines multiple separate connection members into a single integrated power switching module. The module integrates electrical connection terminals, mechanical coupling structures, and control elements into one unified component that attaches to the battery module, eliminating the need for separate mechanical and electrical connection operations.
Solution Approach 2:
The power switching module is designed with segmented control elements that can be independently mounted on the insulative substrate. This segmentation allows for modular assembly where each control element can be positioned and connected separately, simplifying the assembly process while maintaining full control capability.
4Volume of stationary object
If the battery module is constructed in a compact structure to fit limited inner space, then the space utilization is improved, but the structural stability against external force decreases
Solution Approach 1:
The power switching module employs an insulative substrate that provides both electrical insulation and mechanical support. This composite structure combines materials with different properties to achieve both compact size and structural strength, allowing the module to maintain stability while fitting within limited spaces.
Solution Approach 2:
The frame member is designed to fix the outer edges of the battery module assembly in advance, providing pre-reinforcement against external forces. This preliminary structural support is built into the compact design, ensuring stability is maintained even at reduced size.
Data Source
AI summary
Disclosed is a power switching module for a battery module assembly in which a plurality of rectangular battery modules, each having a plurality of battery cells or unit modules connected in series to each other, are stacked in the width (longitudinal) and height (transverse) direction by at least twos such that the battery modules constitute a hexahedral structure (hexahedral stack), outer edges of the hexahedral stack are fixed by a frame member, and input and output terminals of the battery modules are oriented such that the input and output terminals of the battery modules are directed toward one surface (a) of the stack, wherein the power switching module comprises an insulative substrate mounted to the surface (a) of the stack, elements mounted on the substrate for controlling voltage and current during charge and discharge of the battery modules, and connection members mounted on the substrate for interconnecting the control elements.