Battery Module Bus Bar Layout to Eliminate Connection Dead Space
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Solution Overview
Problem
Conventional battery modules require dead space for electrical connections of electrode leads, which reduces energy density and overall capacity.
Innovation Solution
A battery module design featuring electrode leads protruding from both sides of a battery cell, covered by a cell case with integrated bus bars that eliminate the need for internal dead space by allowing external welding, thereby increasing energy density and capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrode leads are stacked inside the module case for welding, then electrical connection is achieved, but dead space is created that reduces energy density
Solution Approach 1:
The patent extracts the electrode leads from the internal stacking arrangement and repositions them to protrude externally from the battery cell. The bus bars are configured to connect to these externally protruding leads, eliminating the need for internal dead space while maintaining electrical connection functionality.
Solution Approach 2:
The patent transitions from a two-dimensional internal stacking arrangement to a three-dimensional configuration where bus bars extend vertically from the module case. This dimensional change allows electrical connections to be made externally without consuming internal space, effectively moving the connection function to a different spatial dimension.
2Ease of manufacture
If dead space is allocated for electrode lead connection, then welding space is provided, but the capacity of the battery module is deteriorated
Solution Approach 1:
The welding function is extracted from the internal battery cell space and relocated to the external bus bar structure. The bus bars serve as the welding substrate, removing the requirement for internal dead space and thereby preserving battery capacity while maintaining manufacturing capability.
Solution Approach 2:
The bus bars act as an intermediary component that facilitates the welding process externally. Instead of welding electrode leads directly inside the module case, the bus bars serve as a mediator that connects to the protruding electrode leads, enabling welding operations without compromising internal battery space.
3Reliability
If electrode leads are disposed inside the module case, then electrical connection is enabled, but space utilization is reduced
Solution Approach 1:
The electrode leads are extracted from the internal disposal arrangement and repositioned to protrude externally from the battery cell. This extraction eliminates the need for internal space allocation while maintaining electrical connection functionality, thereby improving overall space utilization within the module.
Solution Approach 2:
Instead of the conventional approach where electrode leads are disposed inside the module case, the patent inverts this arrangement by having the leads protrude externally. This inversion allows the bus bars to connect to the leads from the outside, maximizing internal space utilization while maintaining electrical connection reliability.
Data Source
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AI summary
Disclosed is a battery module, which includes: at least one battery cell having electrode leads protruding at both sides thereof; and at least one cell case configured to cover both sides and an upper side of the at least one battery cell and including a pair of bus bars having one end connected to the electrode lead and the other end exposed upwards.