Battery Module Busbar Frame Layout for Lower Pack Height
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Solution Overview
Problem
Existing battery modules and packs face challenges in efficiently utilizing space, leading to reduced capacity and increased costs due to the vertical height of busbar frames and the need for excessive thermal conductive resin.
Innovation Solution
The battery module design incorporates busbar frames with guide grooves and adjusting portions that allow electrode leads to be obliquely bent, reducing the overall height and minimizing the use of thermal conductive resin, while maintaining electrical connections through busbars and a sensing unit for voltage and temperature monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If busbar frames are positioned vertically to maintain electrical connections, then electrical reliability is improved, but the overall height of the battery module increases and spatial efficiency deteriorates
Solution Approach 1:
The patent transitions the busbar frame arrangement from a vertical orientation to a horizontal orientation, changing the dimensional arrangement of electrical connections. This allows the electrode leads to be routed horizontally through guide grooves in the busbar frames, reducing the vertical height requirement while maintaining electrical connectivity through the busbars that extend horizontally to contact the electrode leads at the lower edges of the battery cells.
2Temperature
If sufficient thermal conductive resin is applied to ensure heat dissipation, then thermal management is improved, but material costs increase and excess material is used
Solution Approach 1:
The patent applies thermal conductive resin selectively at specific locations where heat dissipation is most critical - namely at the contact points between the busbar frames and the electrode leads, and at the interface between the battery cell stack and the module frame. This localized application ensures effective heat transfer pathways are established without requiring excessive resin throughout the entire module, thereby reducing material consumption while maintaining thermal management performance.
Data Source
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AI summary
A battery module according to an embodiment of the present invention includes: a battery cell stack in which a plurality of battery cells including protruded electrode leads are stacked; a module frame that houses the battery cell stack; and busbar frames disposed to a front and a rear of the battery cell stack where the electrode leads are protruded. The battery cell includes protrude portions respectively formed at both ends of a lower edge of the battery cell. At least one of the busbar frames includes a guide portion extending to a lower surface of the battery cell stack. A guide groove into which the protrude portion is inserted is formed in the guide portion, and the guide groove includes an adjusting portion of which a width becomes narrower from where the battery cell is positioned to where the busbar frame is positioned.