Battery Cell Module Assembly with Wire-Bonded Sensing Busbars
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Solution Overview
Problem
Conventional battery module assembly processes for secondary batteries, such as soldering, bolting, and riveting, are complex and time-consuming, especially with multiple cables, making it difficult to create a simple and compact battery pack with effective voltage and temperature sensing.
Innovation Solution
A cell module assembly with a cell frame, busbar plates, and a sensing unit connected via wire bonding, featuring a printed circuit board and thermistors for temperature measurement, allowing for efficient voltage and temperature sensing while maintaining high durability and compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering, bolting, and riveting processes are used to connect terminals to metal plates, then connection durability is improved, but manufacturing complexity and time increase significantly
Solution Approach 1:
The patent extracts the complex harness cable wiring structure and replaces it with a simplified sensing unit that directly contacts the busbar plates. By removing the intermediate cables and connectors, the invention eliminates soldering, bolting, and riveting processes while maintaining reliable electrical connection through direct contact between the sensing unit and busbar plates.
Solution Approach 2:
The patent replaces mechanical connection methods (soldering, bolting, riveting) with a direct contact electrical connection system. The sensing unit makes direct electrical contact with the busbar plates through wire bonding or conductive adhesive, substituting complex mechanical assembly processes with simpler electrical connection techniques.
2Measurement precision
If multiple cables are used in the harness cable, then voltage sensing capability is improved, but wiring complexity and assembly time increase
Solution Approach 1:
The patent merges multiple separate cable connections into a single integrated sensing unit. Instead of using multiple individual cables to connect different voltage measurement points, the invention uses one sensing unit with multiple contact points that simultaneously establish electrical connections with the busbar plates, thereby maintaining full voltage sensing capability while dramatically reducing assembly time.
Solution Approach 2:
The sensing unit serves multiple functions simultaneously: it provides voltage sensing for multiple battery cells, establishes electrical connections with the busbar plates, and integrates temperature sensing capabilities. This multi-functional design eliminates the need for separate cables and connectors for each sensing point.
3Ease of operation
If additional design structures are added to route and secure harness cables, then cable management is improved, but battery pack compactness and simplicity deteriorate
Solution Approach 1:
The patent removes the entire harness cable system including cable ties, cable holders, clips, and wiring grooves. By extracting these auxiliary structures and replacing them with a compact sensing unit that integrates all sensing functions, the invention eliminates the need for complex cable routing and securing mechanisms while maintaining effective voltage and temperature monitoring.
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 simplifies the connection and assembly of battery components, enhances durability and safety by centralizing electrical connections and sensing components, and facilitates effective heat dissipation within the battery pack.
Implementation Method 1
a sensing unit disposed on the other outer surface of the cell frame and electrically connected to the busbar plates by wire bonding
Implementation Method 2
temperature sensing members coupled to the printed circuit board to measure temperatures of at least some of the battery cells spaced apart by a predetermined distance
Data Source
AI summary
A cell module assembly according to the present disclosure includes a plurality of battery cells; a cell frame accommodating the plurality of battery cells; busbar plates disposed on one outer surface of the cell frame to electrically connect the plurality of battery cells; and a sensing unit disposed on the other outer surface of the cell frame and electrically connected to the busbar plates by wire bonding.