Stacked Battery Module Layout With Simplified Cell Sensing
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Solution Overview
Problem
Conventional battery modules have limited space utilization and design flexibility due to single-layered battery cell arrangements, and they require complex connector structures for sensing, which complicates manufacturing and increases costs.
Innovation Solution
An expandable battery module design that stacks battery cells in both the longitudinal and thickness directions, using a simplified sensing structure with a sensing line and plate that eliminates the need for complex connectors, allowing direct sensing and easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If battery cells are arranged in a single layer in the thickness direction, then the structure is simple, but space utilization is low and design flexibility is limited
Solution Approach 1:
The patent transitions from a single-layer arrangement to a multi-layer stacked configuration in the thickness direction. Multiple battery cell assemblies are stacked vertically, utilizing the third dimension (thickness direction) to increase space utilization while maintaining manufacturing simplicity through modular assembly
2Object-affected harmful factors
If a single battery cell is ignited, then the ignition source is localized, but flames propagate easily to other battery cells causing rapid burnout
Solution Approach 1:
The patent divides the battery module into multiple independent battery cell assemblies, each containing a limited number of battery cells (e.g., 2-4 cells per assembly). This segmentation creates physical and thermal barriers between assemblies, preventing flame propagation from one assembly to others, thus improving safety while maintaining compact design
3Reliability
If a connector with male and female coupling structure is used for sensing, then electrical connection is achieved, but the structure becomes complex and manufacturing cost increases
Solution Approach 1:
The patent extracts the sensing function from the power connection function. Separate sensing lines are used exclusively for electrical property sensing, while power connections use simple busbars. This separation eliminates the need for complex multi-function connectors, reducing structural complexity and manufacturing cost while maintaining reliable sensing capability
4Reliability
If busbars and harnesses are used for sensing between adjacent modules, then electrical connection is established, but assembly operation becomes complicated requiring laser welding and fixing
Solution Approach 1:
The patent merges the sensing line connection with the module stacking structure. Sensing lines are routed through the stacking direction and connected at module ends, allowing adjacent modules to be connected simply by stacking them together. This integration eliminates separate assembly operations for busbars and harnesses, removing the need for laser welding and complex fixing procedures
Data Source
AI summary
The battery module according to the present disclosure includes: a battery cell assembly in which two or more longitudinal unit cells, each of which is composed of two or more battery cells having leads provided at both ends in the longitudinal direction and arranged in a row in the longitudinal direction, are stacked in a thickness direction of the battery cell; a module case in which the battery cell assembly is accommodated; a sensing line electrically connected to the electrode lead of a battery cell included in the battery cell assembly, and having one end exposed to an outside of the module case; and a sensing plate that is coupled to one end of the sensing line exposed to the outside.