Integrated Voltage Sensing Member for Battery Modules
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Solution Overview
Problem
The assembly and connection of voltage sensing units in battery modules are complex, leading to potential short circuits and increased system size due to the need for multiple wires and mechanical coupling members, which complicates the manufacturing process and reduces structural stability, especially in large-sized battery modules used in vehicles.
Innovation Solution
A voltage sensing member with linear mounting parts and conductive compression springs that are securely attached to the battery module's lower case, allowing for elastic contact with electrode terminals and direct electrical connection to the BMS, simplifying assembly and maintaining stable contact under external impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sensing unit is connected to battery cells using multiple wires and mechanical coupling members, then voltage sensing capability is achieved, but the assembly process becomes complex and system size increases
Solution Approach 1:
The patent combines the mechanical coupling function and electrical connection function into a single integrated member. The coupling member includes both mechanical coupling parts for structural support and conductive parts for electrical connection, eliminating the need for separate wires and mechanical couplings, thus simplifying the assembly process while maintaining sensing capability
Solution Approach 2:
The coupling member is designed to perform multiple functions simultaneously: mechanical coupling between battery cells, electrical connection for current flow, and voltage sensing through integrated sensing parts. This multi-functional design reduces the number of components needed and simplifies the overall system structure
2Reliability
If multiple wires are used for attaching the sensing unit to battery cells, then voltage sensing is enabled, but short circuits may occur and assembly complexity increases
Solution Approach 1:
The patent integrates the electrical connection function into the mechanical coupling member itself, eliminating separate wires that could cause short circuits. The conductive parts are precisely positioned within the coupling member to establish reliable electrical connections without the hazards of loose wire connections
Solution Approach 2:
The coupling member acts as an intermediary structure that safely mediates the electrical connection between battery cells. Instead of using exposed wires that could cause short circuits, the electrical connection is embedded within the structured coupling member, which provides inherent protection against short circuit hazards
3Stability of the object's composition
If mechanical coupling members are used to connect battery cells, then structural stability is achieved, but the total system size increases
Solution Approach 1:
The patent merges the mechanical coupling function and electrical connection function into a single integrated member with reduced dimensions. By combining these functions, the coupling member requires less space than separate mechanical couplings and wires, thereby reducing the overall system volume while maintaining structural stability
Solution Approach 2:
The coupling member is designed with segmented functional zones: mechanical coupling parts for structural support, conductive parts for electrical connection, and sensing parts for voltage detection. This segmentation allows each function to be optimized in a compact arrangement, reducing overall system size while maintaining all necessary functions
4Volume of moving object
If a compact battery module design is implemented, then system size is reduced, but space for coupling and welding members is limited
Solution Approach 1:
The patent combines mechanical coupling and electrical connection functions into a single integrated member, eliminating the need for separate coupling and welding processes. This integration reduces the space required for assembly operations while maintaining manufacturability, as the combined member can be installed in a single step without requiring additional space for separate coupling and welding operations
Solution Approach 2:
The coupling member is pre-designed and pre-configured with both mechanical coupling features and electrical connection features integrated together. This preliminary integration of functions allows the component to be installed in a compact space without requiring additional assembly operations that would need extra space, thereby facilitating compact module design while maintaining ease of manufacture
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
This solution enables a compact, stable, and efficient voltage sensing system that simplifies the assembly process, reduces system size, and ensures reliable voltage sensing in battery modules, even under vibration and impact, while maintaining high output and capacity.
Implementation Method 1
conductive compression springs that are securely attached to the battery module's lower case, allowing for elastic contact with electrode terminals
Data Source
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AI summary
Disclosed herein is a voltage sensing member constructed in a structure in which linear mounting parts are mounted to supporting parts coupled to the bottom of a battery module, conductive sensing parts are mounted on the mounting parts while the conductive sensing parts are in elastic contact with electrode terminals of battery cells, and the sensing parts are electrically connected to a battery management system (BMS). The voltage sensing member according to the present invention is manufactured by a simple assembly process without using a plurality of members for mechanical coupling and electrical connection. Consequently, the present invention has the effect of reducing the manufacturing costs of the voltage sensing member. Also, the voltage sensing member is maintained in elastic and stable contact when external impact or frequent vibration is applied to the voltage sensing member. Consequently, the present invention has the effect of performing stable voltage sensing operation. Furthermore, the present invention has the effect of manufacturing a middle- or large-sized battery pack having desired output and capacity using a battery module including the voltage sensing member as a unit body.