U-Shaped Battery Module Frame With Hinged Sensor Bridge
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Solution Overview
Problem
Conventional battery modules suffer from increased size and weight due to the use of cover plates and flexible printed circuits, which hinder efficient space utilization and affect vehicle performance and fuel efficiency.
Innovation Solution
A U-shaped frame structure with integrated bus bar frames and a flexible flat cable connection, along with a temperature sensor attached to a hinged bridge, replaces the cover plate and flexible printed circuit, reducing height and weight while maintaining electrical connectivity and temperature sensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cover plate and flexible printed circuit are used to protect the battery cell stacked body and provide electrical connection, then the reliability and protection are improved, but the height and weight of the battery module increase
Solution Approach 1:
The bus bar frame is merged with the cover plate structure to form an integrated component. The bus bar frame serves dual functions: providing mechanical protection as a cover plate and enabling electrical connection between battery cells, thereby eliminating the need for separate flexible printed circuits and reducing overall module height
Solution Approach 2:
The bus bar frame is designed to perform multiple functions simultaneously: it acts as a protective cover plate for the battery cell stacked body, provides electrical connection pathways, and serves as a structural support element. This multi-functionality reduces the number of separate components needed, thereby reducing height and weight
2Ease of manufacture
If a monoframe structure with large height is designed to accommodate battery cell stacked body and assembly clearance, then the ease of manufacture and assembly stability are improved, but the space utilization rate deteriorates
Solution Approach 1:
The frame structure is designed with flexible positioning capabilities that allow adaptation to manufacturing tolerances and assembly variations. The frame can accommodate slight variations in battery cell dimensions and positioning while maintaining stable assembly, eliminating the need for excessive clearance and improving space utilization
Solution Approach 2:
The frame dimensions and clearance requirements are optimized by changing the design parameters to match actual manufacturing capabilities. By adjusting the frame height and positioning tolerances to realistic values rather than excessive clearances, the space utilization rate is improved while maintaining adequate assembly stability
3Reliability
If the battery module height is increased to accommodate protective components and assembly clearance, then the protection and assembly stability are improved, but the energy density and vehicle performance deteriorate
Solution Approach 1:
Protective functions and electrical connection functions are merged into the bus bar frame structure, eliminating the need for separate cover plates and flexible printed circuits. This integration reduces the overall module height, increasing the volume available for active battery cells and thereby improving energy density
Solution Approach 2:
The unnecessary protective components (separate cover plate and flexible printed circuit) are extracted from the design. The bus bar frame alone provides sufficient protection and electrical connection, removing excess height and weight that would reduce energy density and vehicle performance
Data Source
AI summary
A battery module according to an exemplary embodiment of the present invention includes: a battery cell stacked body in which a plurality of battery cells are stacked; a U-shaped frame receiving the battery cell stacked body and having an opened upper part; an upper plate covering the battery cell stacked body on the opened upper part of the U-shaped frame; a bus bar frame respectively formed at both ends of the battery cell stacked body; a signal connection portion disposed between the upper plate and the battery cell stacked body and connecting the bus bar frames respectively formed at both ends of the battery cell stacked body; and a bridge adjacent to the signal connection portion and hinged to the bus bar frame, wherein a temperature sensor is attached to the bridge.