Battery Module Busbar Frame for Swelling-Induced Lead Stress
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Solution Overview
Problem
Existing secondary battery modules are prone to electrode lead disconnection due to tensile forces generated by swelling or impacts, which can render the entire module inoperable.
Innovation Solution
A secondary battery module design incorporating a moving frame connected to a fixed frame via supports that allow tilting and pivoting movements, with elastic supports to accommodate tensile forces and restore the electrode leads to their original position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrode lead is fixed to the busbar to restrict movement, then electrical connection stability is improved, but vulnerability to tensile force from swelling or impact increases
Solution Approach 1:
The busbar is designed with a flexible portion that can dynamically deform in response to tensile forces from battery swelling or impact. This flexible section acts as a shock absorber, allowing the busbar to move and accommodate the expansion forces without transmitting excessive stress to the electrode lead connection points, thereby maintaining electrical connection stability while resisting tensile force damage.
Solution Approach 2:
The busbar's physical parameters are changed by introducing a flexible portion with different rigidity characteristics compared to the rigid portions. This creates a gradient structure where the flexible section has higher elasticity and lower stiffness, enabling it to deform under tensile stress while the rigid sections maintain structural integrity and electrical connection stability.
2Strength
If the busbar is made rigid to maintain structural stability, then mechanical strength is improved, but ability to accommodate swelling or impact forces decreases
Solution Approach 1:
The busbar is segmented into distinct functional portions: rigid portions for maintaining structural stability and electrical connection, and a flexible portion for accommodating deformation. This segmentation allows each section to perform its specialized function - the rigid parts provide mechanical strength while the flexible part provides adaptability to swelling and impact forces.
Solution Approach 2:
Different portions of the busbar are given different local qualities - the rigid portions have high stiffness and strength for structural support, while the flexible portion has high elasticity and low stiffness for shock absorption. This local differentiation of material properties allows the busbar to simultaneously achieve both structural stability and adaptability to external forces.
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
Prevents electrode lead disconnection by allowing flexible movement and stable support of electrode leads, maintaining module functionality even under tensile stress.
Implementation Method 1
a moving frame that is connected to the fixed frame through a support fixed to the fixed frame at one end thereof and is capable of tilting and pivoting movements at a point connected to the support
Data Source
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AI summary
The present disclosure provides a secondary battery module in which a cell assembly having a plurality of battery cells with electrode leads protruding from one side stacked is embedded in a main frame, including a fixed frame coupled to the main frame; a moving frame that is connected to the fixed frame through a support fixed to the fixed frame at one end thereof and is capable of tilting and pivoting movements at a point connected to the support; and a busbar coupled to the moving frame and to which the electrode leads are bonded, wherein the moving frame moves together with the electrode leads according to the force acting on the electrode leads.