Battery Module Busbar Guide Groove for Lower Pack Height
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Solution Overview
Problem
There is a need for a battery module that can efficiently utilize space and increase energy capacity, particularly in battery packs used for portable devices and electric vehicles, where existing designs face challenges in optimizing the use of available space and reducing the height of the module.
Innovation Solution
The battery module incorporates a battery cell stack with protruded electrode leads, a module frame, and busbar frames with guide grooves and adjusting portions that allow the electrode leads to be inclined, reducing the module's height and enabling more efficient use of space, while also reducing the amount of thermally conductive resin required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the battery module uses conventional straight electrode leads, then the assembly is simple, but the module height increases and space utilization decreases
Solution Approach 1:
The electrode leads are designed with curved or inclined configurations instead of straight lines. The guide grooves in the busbar frame provide curved pathways that guide the electrode leads from the battery cells to the busbar, reducing the vertical height requirement while maintaining electrical connectivity.
Solution Approach 2:
The electrode leads are directed to extend in horizontal directions rather than purely vertical directions. By utilizing the guide grooves that extend in the horizontal direction from the battery cell stack to the busbar frame, the design transforms the spatial arrangement from a vertical stacking approach to a more distributed three-dimensional layout, improving space utilization.
2Length of stationary object
If the battery module uses inclined electrode leads, then the height is reduced, but the assembly complexity increases
Solution Approach 1:
The guide grooves in the busbar frame serve as intermediary structures that facilitate the inclined positioning of electrode leads. These grooves provide pre-defined pathways that guide the electrode leads during assembly, eliminating the need for complex manual positioning or additional alignment fixtures.
Solution Approach 2:
The guide grooves are designed with specific geometric parameters (width, depth, inclination angle) that change along their length. The width of the guide groove decreases from the opening toward the bottom, and the groove provides lateral constraints that automatically position the electrode leads at the correct inclination angle, simplifying the assembly process.
3Temperature
If more thermally conductive resin is used, then thermal management is improved, but the cost and material usage increase
Solution Approach 1:
The inclined electrode leads and guide groove structure create more uniform heat distribution patterns within the battery module. By reducing height and improving spatial arrangement, the thermal pathways are optimized to conduct heat more efficiently from the battery cells to the cooling plates, reducing the need for excessive thermally conductive resin in non-critical areas.
Data Source
AI summary
A battery module and a battery pack including the same are provided. The battery module includes a battery cell stack in which a plurality of battery cells including protruded electrode leads are stacked, the battery cell including protruding portions respectively formed at both ends of a lower edge of the battery cell, 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, at least one of the busbar frames including a guide portion extending to a lower surface of the battery cell stack, the guide portion comprising a guide groove into which the protruding portion is inserted, and the guide groove including an adjusting portion of which a width becomes narrower from where the battery cell is positioned to where the busbar frame is positioned.