WO2024172308A1

WO2024172308A1 - Battery system assembly

Info

Publication number: WO2024172308A1
Application number: PCT/KR2024/000722
Authority: WO
Inventors: 최병기; 강지웅
Original assignee: 주식회사 카펙발레오
Priority date: 2023-02-15
Filing date: 2024-01-15
Publication date: 2024-08-22
Also published as: KR20240127182A

Abstract

The present invention provides a battery system assembly comprising: a battery module including a plurality of battery cells and a sensing block which is configured to sense state information related to operation states of the battery cells; and a management module including a cell monitoring unit which is connected to the sensing block through a board-to-board connection and receives the state information, and a battery management unit which is connected to the cell monitoring unit via wireless communication and receives the state information.

Description

Battery System Assembly

The present invention relates to a battery system assembly used as an energy source in various devices.

Secondary batteries are widely used as an energy source for mobile devices. In addition, secondary batteries are also attracting attention as a power source for electric vehicles (EVs) and hybrid electric vehicles (HEVs).

The basic unit of a secondary battery is a battery cell. While one or two battery cells are used in small mobile devices, a battery system assembly is used in medium and large devices such as automobiles. A battery system assembly electrically connects multiple battery modules to achieve high output and large capacity.

The main design criterion of a battery system assembly is energy density. Energy density is the amount of energy per unit volume or unit weight, and is an indicator of the efficiency of a battery system assembly. In electric vehicles, energy density is a factor that determines the driving range of the vehicle.

In order to increase energy density, the volume or weight of the battery assembly system needs to be reduced. Existing battery assembly systems extensively use wire harnesses for communication between battery modules, making it difficult to further improve energy density. This is because the weight and volume of the harness cannot be reduced any further.

The background technology described above is technical information that the inventor possessed for deriving embodiments of the present invention or acquired in the process of deriving them, and cannot necessarily be said to be publicly known technology disclosed to the general public prior to the present application.

One object of the present invention is to provide a battery system assembly capable of improving energy density by reducing volume and weight compared to existing systems.

According to one aspect of the present invention for achieving the above-described task, a battery system assembly may include a battery module having a plurality of battery cells and a sensing block configured to detect status information related to an operating state of the battery cells; and a management module having a cell monitoring unit connected to the sensing block in a board-to-board manner to receive the status information, and a battery management unit connected to the cell monitoring unit in wireless communication to receive the status information.

Here, the sensing block may include a sensing board and a first connector, and the cell monitoring unit may include a monitoring board and a second connector directly connected to the first connector.

Here, the battery module may further include a mounting cover disposed between the sensing block and the cell monitoring unit.

Here, the battery module may further include a mounting member formed to secure the cell monitoring unit to the sensing block.

Here, the mounting member may include a mounting protrusion formed to protrude from the sensing block toward the cell monitoring unit.

Here, the cell monitoring unit may further include a mounting bracket that contacts the mounting protrusion at a position where the first connector and the second connector are directly connected.

Here, the cell monitoring unit may further include a fastening piece for fastening the mounting bracket to the mounting protrusion.

Here, the mounting cover may form a first communication channel allowing connection between the mounting member and the cell monitoring unit.

Here, the mounting cover includes a cover body, and the first communication channel can be formed in a form in which a portion of the cover body is removed.

Here, the first communication channel may include an opening formed in the cover body.

Here, the mounting cover may form a second communication channel that allows connection between the first connector and the second connector.

Here, the mounting cover includes a cover body, and the second communication channel can be formed in a form in which a portion of the cover body is removed.

Here, the second communication channel may include an opening formed in the cover body.

Here, the battery module may further include a mounting cover disposed between the sensing block and the cell monitoring unit, and the cell monitoring unit may further include an antenna, and the mounting cover may include an accommodation space formed to accommodate the antenna.

Here, the mounting cover further includes a cover body having a size corresponding to the plurality of battery cells, and the receiving space can be formed at an upper corner of the cover body.

A battery system assembly according to one aspect of the present invention comprises: a battery module having a plurality of battery cells, a sensing block configured to detect status information related to an operating state of the battery cells, and a mounting cover disposed on an opposite side of the plurality of battery cells with respect to the sensing block; and a management module having a cell monitoring unit electrically and mechanically connected to the sensing block to receive the status information, and a battery management unit connected to the cell monitoring unit to receive the status information, wherein the mounting cover forms a communication channel, and at least one of an electrical connection and a mechanical connection between the sensing block and the cell monitoring unit can be formed through the communication channel.

Here, the communication channel includes a first communication channel, and the battery module further includes a mounting member formed to secure the cell monitoring unit to the sensing block, and the cell monitoring unit and the mounting member can be connected to each other through the first communication channel to form the mechanical connection.

Here, the mounting member may include a mounting projection formed to protrude toward the cell monitoring unit so as to be inserted into the first communication channel.

Here, the sensing block has a sensing board and a first connector, the cell monitoring unit has a monitoring board and a second connector connected to the first connector, the communication channel includes a second communication channel, and the first connector and the second connector can be connected to each other through the second communication channel to form the electrical connection.

Here, the cell monitoring unit and the battery management unit can be connected via wireless communication.

Here, the sensing block includes a first sensing block and a second sensing block respectively corresponding to opposite ends along the longitudinal direction of the battery cell, and the battery module may further include a wired connection structure formed by a flat cable and connecting the first sensing block and the second sensing block.

A battery system assembly according to one aspect of the present invention comprises: a battery module having a plurality of battery cells, a first sensing block and a second sensing block respectively connected to opposite ends of the battery cells along a longitudinal direction for detecting status information related to an operating state of the battery cells, and a wired connection structure connected to at least one of the first sensing block and the second sensing block; and a management module having a battery management unit wirelessly connected to the cell monitoring unit to receive the status information, wherein the first sensing block comprises a first sensing board and a first connector formed on the first sensing board, and the cell monitoring unit comprises a monitoring board and a second connector formed on the monitoring board and connected to the first connector, and the wired connection structure may include a circuit connection member formed as a flat cable and connecting the first sensing block and the second sensing block.

Here, the circuit connection member can be connected to at least one of the first sensing block and the second sensing block in a substrate direct connection manner.

Here, the wired connection structure includes a temperature measuring member configured to measure the temperature of the battery cell, and the temperature measuring member includes a first part connected to the first sensing block and formed of a flat cable; and a second part connected to the first part and formed of a flexible circuit board, and the second part may further include a temperature measuring device mounted on the flexible circuit board.

Here, the first connector can be connected to the second connector in a board-to-board manner.

According to the battery system assembly according to the present invention configured as described above, the sensing block of the battery module and the cell motoring unit of the management module are connected in a board-to-board manner, and the cell monitoring unit and the battery management unit are connected via wireless communication, so that the wire harness, connector, etc. required for these connections are eliminated or reduced. In addition, the volume and weight occupied by the components combined by these connections are also reduced. Accordingly, the energy density of the battery system assembly can be greatly improved compared to the existing one.

FIG. 1 is a conceptual diagram for explaining a communication method of a management module in a battery system assembly according to one embodiment of the present invention.

FIG. 2 is a perspective view showing a portion of a battery system assembly according to one embodiment of the present invention.

Figure 3 is an exploded perspective view of the battery module and cell monitoring unit of Figure 1.

FIG. 4 is a partially exploded perspective view illustrating the coupling method between the battery module and the cell monitoring unit of FIG. 3.

Figure 5 is a plan view showing a board-to-board connection method between a battery module and a cell monitoring unit.

FIG. 6 is a perspective view of the connection between the first sensing block, the second sensing block, and the wired connection structure of FIG. 2.

Fig. 7 is a partially exploded perspective view showing the coupling method between the first sensing block and the wired connection structure in Fig. 6.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the attached drawings.

The present invention is not limited to the embodiments disclosed below, but can be implemented in various forms and with various modifications. However, these embodiments are provided to ensure that the disclosure of the present invention is complete and to fully inform those skilled in the art of the scope of the invention. Therefore, the present invention is not limited to the embodiments disclosed below, but should be understood to include all modifications, equivalents, or substitutes included in the technical spirit and scope of the present invention, as well as substituting or adding the configuration of one embodiment with the configuration of another embodiment.

The attached drawings are only intended to facilitate understanding of the embodiments disclosed in this specification, and the technical ideas disclosed in this specification are not limited by the attached drawings, and should be understood to include all modifications, equivalents, or substitutes included in the spirit and technical scope of the present invention. In the drawings, the components may be expressed exaggeratedly large or small in size or thickness for convenience of understanding, but the protection scope of the present invention should not be construed as being limited due to this.

The terminology used herein is only used to describe specific implementations or examples and is not intended to limit the present invention. And the singular expression includes the plural expression unless the context clearly indicates otherwise. In the specification, terms such as "comprises", "consists of", etc. are intended to specify the presence of a feature, number, step, operation, component, part or combination thereof described in the specification. That is, it should be understood that terms such as "comprises", "consists of", etc. do not exclude in advance the possibility of the presence or addition of one or more other features, numbers, steps, operations, components, parts or combinations thereof.

Terms that include ordinal numbers, such as first, second, etc., may be used to describe various components, but the components are not limited by the terms. The terms are used only to distinguish one component from another.

When it is said that a component is "connected" or "connected" to another component, it should be understood that it may be directly connected or connected to that other component, but that there may be other components in between. On the other hand, when it is said that a component is "directly connected" or "directly connected" to another component, it should be understood that there are no other components in between.

When a component is referred to as being "above" or "below" another component, it should be understood that it is not only positioned directly above that other component, but that there may also be other components intervening there.

Unless otherwise defined, all terms used herein, including technical or scientific terms, have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Terms defined in commonly used dictionaries, such as those defined in common usage, should be interpreted as having a meaning consistent with the meaning they have in the context of the relevant art, and shall not be interpreted in an idealized or overly formal sense unless expressly defined in this application.

FIG. 1 is a conceptual diagram for explaining a communication method of a management module in a battery system assembly according to one embodiment of the present invention, and FIG. 2 is a perspective view showing a part of a battery system assembly according to one embodiment of the present invention.

Referring to these drawings, the battery system assembly includes a battery module (100), a management module (200), and a case (300).

The battery module (100) has a plurality of battery cells (110, see FIG. 3). Status information related to the operating status of the battery cells (110) is detected by the sensing block (130). The status information may be, for example, voltage, temperature, etc. of the battery cells (110). The battery module (100) is provided in multiple units.

The management module (200) is configured to control the battery module (100), specifically, the battery cell (110), based on the status information. The management module (200) specifically includes a cell monitoring unit (210) and a battery management unit (250). The cell monitoring unit (210) is connected to the sensing block (130). The cell monitoring unit (210) is configured to receive the status information and transmit it to the battery management unit (250). The battery management unit (250) issues a command to the cell monitoring unit (210) based on the status information. The cell monitoring unit (210) maintains electrical balancing between the battery cells (110) according to the command. While the sensing block (130) and the cell monitoring unit (210) are physically connected to enable communication, the cell monitoring unit (210) and the battery management unit (250) may be connected via wireless communication. A plurality of cell monitoring units (210) are provided, and one is allocated to each battery module (100). In contrast, a single battery management unit (250) is provided, and can control a plurality of cell monitoring units (210).

The case (300) constitutes a space in which the battery module (100) and the management module (200) are mounted. The case (300) may have a cross beam (310). A mounting bracket (143) of the battery module (100) may be placed on the cross beam (310). The mounting bracket (143) is fixed to the cross beam (310) by a fastening piece (144).

According to this configuration, the battery management unit (250) and the plurality of cell monitoring units (210) can be connected wirelessly without a wire harness. By excluding the wire harness, the weight and volume of the battery system assembly can be greatly reduced.

The cell monitoring unit (210) is coupled to the battery module (100) in such a way that the gap with the battery module (100) is narrowed. As a result, the space occupied by the battery module (100) and the cell monitoring unit (210) can be minimized. This structure allows a tool for handling the fastening piece (144) to enter between two adjacent battery modules (100), along with the overall space saving of the battery system assembly.

The specific structure of the battery module (100) and the cell monitoring unit (210) is described with reference to FIGS. 3 and 4.

Referring to this drawing, the battery module (100) includes a plurality of battery cells (110) and a top cover (120).

The battery cells (110) are arranged along the longitudinal direction (L). The longitudinal direction (L) refers to the direction in which the battery cells (110) are extended. A plurality of battery cells (110) are arranged adjacent to each other and are also covered by a top cover (120). The top cover (120) covers the upper surface and both side surfaces of the battery cells (110). A small-sized strap (160) is mounted on the bottom surface of the battery cells (110), so that most of the area of the bottom surface is exposed to the outside.

A sensing block (130) and a mounting cover (140) are sequentially connected to both ends along the longitudinal direction (L) of the battery cell (110). The sensing block (130) has a first sensing block (131) and a second sensing block (136). The first sensing block (131) has a bus bar (133) and a (first) sensing board (135). The bus bar (133) is connected to an electrode lead (115) of the battery cell (110) and detects voltage information of the battery cell (110). The sensing board (135) is connected to the bus bar (133) and receives the voltage information. The second sensing block (130) has a bus bar (see 133), but does not have a sensing board (135). The mounting cover (140) has a first mounting cover (141) that surrounds the first sensing block (131) and a second mounting cover (146) that surrounds the second sensing block (130).

A wired connection structure (150) is connected to the first sensing block (131) and the second sensing block (130). The wired connection structure (150) may be arranged between the battery cell (110) and the top cover (120). The wired connection structure (150) is formed of a flat cable, a flexible printed circuit board (FPCB), or the like, and contributes to reducing the size of the battery module (100) along the height direction (H). Here, the height direction (H) is a direction from the bottom surface of the battery cell (110) toward the top surface, and is a direction perpendicular to the length direction (L).

Among these battery modules (100), a cell monitoring unit (210) is coupled to a sensing block (130), specifically, a first sensing block (131). The cell monitoring unit (210) is located on the opposite side of the sensing block (130) with respect to a mounting cover (140), specifically, a first mounting cover (141).

The coupling method between the sensing block (131) and the cell monitoring unit (210) is described with reference to FIGS. 4 and 5.

FIG. 4 is a partially exploded perspective view illustrating a method of coupling between the battery module and the cell monitoring unit of FIG. 3, and FIG. 5 is a plan view showing a board-to-board coupling method between the battery module and the cell monitoring unit.

Referring to the drawings, the mounting cover (141) is arranged to surround the sensing block (131). A first connector (137) is mounted on the sensing board (135) of the sensing block (131). The sensing block (131) is also provided with a mounting member. The mounting member may be a mounting protrusion (139) that protrudes along the longitudinal direction (L). The mounting member may have a different shape than a protruding structure such as the mounting protrusion (139). For example, the mounting member may be a receptacle that is coupled with a hook.

The cell monitoring unit (210) has a monitoring board (211). An antenna (213) for wireless communication with a battery management unit (250) is installed on the monitoring board (211). A second connector (217) connected to a first connector (137) is mounted on the monitoring board (211).

The cell monitoring unit (210) is connected to the sensing block (131) despite the presence of the mounting cover (141). For this connection, the mounting cover (141) has a cover body (142) in which a communication channel (145) is formed. The cover body (142) has a main surface (142a) and a side surface (142b) bent from the main surface (142a). The main surface (142a) and the side surface (142b) have sizes corresponding to a plurality of battery cells (110).

The communication channel (145) may have a first communication channel (145a) to a third communication channel (145c). The first communication channel (145a) is for mechanical connection between the sensing block (131) and the cell monitoring unit (210). The second communication channel (145b) is for electrical connection between them. The third communication channel or receiving space (145c) is for receiving the antenna (213).

In this embodiment, the first communication channel (145a) to the third communication channel (145c) are illustrated as openings, but are not limited thereto. For example, the space formed between the cover body (142) and the adjacent configuration of the battery module (100) may become the first communication channel (145a) to the third communication channel (145c). In that case, the cover body (142) will have a size smaller than the size illustrated in this drawing. In addition, the first communication channel (145a) to the third communication channel (145c) may have a form in which a portion of the corner region of the cover body (142) is removed.

In the first communication channel (145a), a mounting protrusion (139) can be inserted. In response to the mounting protrusion (139), the cell monitoring unit (210) has a mounting bracket (214). The mounting protrusion (139) and the mounting bracket (214) are fastened by a fastening piece (215). The first communication channel (145a), the mounting protrusion (139), the mounting bracket (214), and the fastening piece (215) are provided as a pair. The position where the mounting protrusion (139) and the mounting bracket (214) come into contact is the position where the first connector (137) and the second connector (217) are directly connected.

Unlike the above, the mounting protrusion (139) and the mounting bracket (214) may be joined by welding, riveting, bonding, thermal fusion, etc. Furthermore, when the mounting protrusion (139) is in a hook shape, a receptacle corresponding to the hook shape may be formed on the mounting bracket (214). In addition, the mounting protrusion (139) may be formed on the cell monitoring unit (210) side, and the mounting bracket (214) may be formed on the sensing block (131) side.

In response to the second communication channel (145b), the first connector (137) and the second connector (217) are positioned. They are physically directly connected to each other through the second communication channel (145b). This connection method is called a board-to-board method.

The accommodation space (145c) can be formed at the upper corner of the cover body (142). The upper corner is a portion where the main surface (142a) and the side surface (142b) meet. An antenna (213) is accommodated in the accommodation space (145c).

According to this configuration, since the cell monitoring unit (210) is mounted on the sensing block (131) rather than the mounting cover (141), the connection between the first connector (137) and the second connector (217) can be made more accurately. If the cell monitoring unit (210) is mounted on the mounting cover (141), the assembly tolerance between the mounting cover (141) and the sensing block (131) accumulates in the assembly tolerance therebetween, so the first connector (137) and the second connector (217) may not be connected at an accurate position.

As the first connector (137) and the second connector (217) are joined in a board-to-board manner, the size of the battery module (100) and the cell monitoring unit (210) along the longitudinal direction (L) is reduced. This enables a tool for handling the fastening piece (144) to enter between adjacent cell monitoring units (210), as described with reference to FIG. 2.

By the location of the receiving space (145c), the antenna (213) can secure an appropriate height required for demonstrating communication performance.

The coupling method between the sensing block (131, 136) and the wired connection structure (150) is described with reference to FIGS. 6 and 7.

FIG. 6 is a perspective view of the connection between the first sensing block, the second sensing block, and the wired connection structure (150) of FIG. 2.

Referring to this drawing, the wired connection structure (150) has a circuit connection member (151) and a temperature measurement member (156).

The circuit connection member (151) connects the first sensing block (131) and the second sensing block (130). To this end, the circuit connection member (151) is arranged along the longitudinal direction (L). The circuit connection member (151) may be formed as a flat cable.

The temperature measuring member (156) is configured to measure the temperature of the battery cell (110). The temperature measuring member (156) is specifically divided into a first part (157) and a second part (158). The first part (157) is connected to the first sensing block (131) and is formed as a flat cable. The first part (157) and the second part (158) can be connected to each other by welding. The second part (158) is connected to the first part (157) and is formed as a flexible circuit board (fpcb). A part of the second part (158) extends along the width direction (W), and the rest extends along the height direction (H). A temperature measuring device (159) can be mounted on the second part (158). Here, the width direction (W) is the direction in which multiple battery cells (110) are sequentially stacked, and is a direction perpendicular to the length direction (L) and the height direction (H).

By adopting this wired connection structure (150), the size of the battery module (100) along the height direction (H) can be further reduced. In addition, the cost can be reduced compared to the case where the entire wired connection structure (150) is manufactured using a flexible circuit board. This is because the cost increases due to the wasted portion when the flexible circuit board is manufactured in a form that is not particularly straight.

Referring to this drawing, the circuit connection member (151) and the temperature measurement member (156) can be connected to the sensing board (135) in a PCB direct connecting manner. To this end, a terminal (not shown) is printed on one area (132) of the sensing board (135). The edge of the area (132) where the terminal is printed is removed, and the connector (153) of the circuit connection member (151) is inserted into the removed area. This connection method can be equally applied to the temperature measurement member (156).

By this direct substrate connection method, the size of the battery module (100) along the longitudinal direction (L) can be reduced. In addition, since there is no need to mount a separate connector on the sensing board (135), the process can be simplified and the cost can be reduced.

The present invention has industrial applicability in the field of manufacturing battery system assemblies.

Claims

A battery module having a plurality of battery cells and a sensing block configured to detect status information related to the operating status of the battery cells; and

A battery system assembly comprising a management module having a cell monitoring unit connected to the sensing block in a board-to-board manner to receive the status information, and a battery management unit connected to the cell monitoring unit via wireless communication to receive the status information.
In the first paragraph,

The above sensing block,

Equipped with a sensing board and a first connector,

The above cell monitoring unit,

A battery system assembly comprising a monitoring board and a second connector directly connected to the first connector.
In the second paragraph,

The above battery module,

A battery system assembly further comprising a mounting cover disposed between the sensing block and the cell monitoring unit.
In the third paragraph,

The above battery module,

A battery system assembly further comprising a mounting member formed to secure the cell monitoring unit to the sensing block.
In paragraph 4,

The above mounting member is,

A battery system assembly comprising a mounting protrusion formed to protrude from the sensing block toward the cell monitoring unit.
In paragraph 5,

The above cell monitoring unit,

A battery system assembly further comprising a mounting bracket fastened to the mounting protrusion at a position such that the first connector and the second connector are directly connected.
In the first paragraph,

The above battery module,

Further comprising a mounting cover disposed between the sensing block and the cell monitoring unit.

The above cell monitoring unit,

Including more antennas,

The above mounting cover,

A battery system assembly comprising a receiving space formed to receive the antenna.
In Article 7,

The above mounting cover,

Further comprising a cover body having a size corresponding to the plurality of battery cells,

The above accommodation space is,

A battery system assembly formed at the upper corner of the above cover body.
A battery module having a plurality of battery cells, a sensing block configured to detect status information related to the operating status of the battery cells, and a mounting cover disposed on an opposite side of the plurality of battery cells with respect to the sensing block; and

A management module including a cell monitoring unit electrically and mechanically connected to the sensing block and receiving the status information, and a battery management unit connected to the cell monitoring unit and receiving the status information,

The above mounting cover,

It forms a communication channel,

A battery system assembly, wherein at least one of an electrical connection and a mechanical connection between the sensing block and the cell monitoring unit is formed through the communication channel.
In Article 9,

The above mounting cover,

Including a cover body,

The above communication channel is,

A battery system assembly, wherein a portion of a corner region of the cover body is removed or a central region of the cover body is opened.
In Article 10,

The above communication channel is,

Including the first communication channel,

The above battery module,

Further comprising a mounting member formed to secure the cell monitoring unit to the sensing block;

The above cell monitoring unit and the above mounting member,

A battery system assembly, which is connected to each other through the first communication channel, thereby forming the mechanical connection.
In Article 11,

The above mounting member is,

A battery system assembly comprising a mounting protrusion formed to protrude toward the cell monitoring unit so as to be inserted into the first communication channel.
In Article 10,

The above sensing block,

Equipped with a sensing board and a first connector,

The above cell monitoring unit,

It has a monitoring board and a second connector connected to the first connector,

The above communication channel is,

Including a second communication channel,

The above first connector and the above second connector,

A battery system assembly, which is connected to each other through the second communication channel, thereby forming the electrical connection.
A battery module having a plurality of battery cells, a first sensing block and a second sensing block respectively connected to both ends along the length of the battery cells to detect status information related to the operating status of the battery cells, and a wired connection structure connected to at least one of the first sensing block and the second sensing block; and

A management module including a battery management unit that is connected to the cell monitoring unit via wireless communication and receives the status information,

The above first sensing block,

It comprises a first sensing board and a first connector formed on the first sensing board,

The above cell monitoring unit,

A monitoring board comprising: a second connector formed on the monitoring board and connected to the first connector;

The above wired connection structure is,

A battery system assembly comprising a circuit connecting member formed of a flat cable and connecting the first sensing block and the second sensing block.
In Article 14,

The above first connector,

A battery system assembly, connected in a board-to-board manner to the second connector.