Battery Module Busbar Insertion Layout for Lower Heat and Height
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Solution Overview
Problem
Existing battery modules face limitations in scalability, serviceability, and heat dissipation due to the use of stacked battery cells, particularly in high-output applications, which affect their performance and recycling.
Innovation Solution
The battery module design includes busbars with insertion holes for electrode terminals, allowing electrical connection through edge welding, reducing heat generation and module height, and increasing power capacity per unit volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional stacked battery cells are used with traditional terminal connection methods, then electrical connection is achieved, but heat generation increases and module height increases
Solution Approach 1:
The electrode terminal is inserted into the busbar, with the terminal nested within the busbar structure. This nesting arrangement allows the terminal to be housed inside the busbar, reducing overall height while maintaining electrical connection functionality.
Solution Approach 2:
The electrical connection transitions from a top-down compression approach to a side-insertion approach. The terminal is inserted horizontally into the busbar through the side, changing the dimensional orientation of the connection and enabling heat dissipation along the insertion direction.
2Temperature
If electrode terminal is inserted into busbar with edge welding, then heat generation is reduced, but manufacturing complexity increases
Solution Approach 1:
The terminal is pre-inserted into the busbar before the welding process. This preliminary positioning ensures proper alignment and placement, allowing the welding operation to proceed efficiently at a specific location (the insertion portion) without requiring complex positioning mechanisms during welding.
Solution Approach 2:
The welding is applied specifically to the insertion portion of the terminal where it enters the busbar, rather than the entire terminal surface. This localized welding approach concentrates the manufacturing process at a specific critical area, simplifying the overall manufacturing while ensuring effective electrical connection.
3Power
If multiple battery cells are stacked to increase capacity, then power output increases, but heat dissipation becomes more difficult
Solution Approach 1:
The battery module is divided into multiple independent battery cell units, each with its own terminal and busbar connection. This segmentation allows heat to be dissipated from each cell independently through its own insertion-hole connection, preventing heat accumulation that would occur in a fully stacked configuration.
Solution Approach 2:
The busbar acts as an intermediary heat dissipation path. Heat generated at the welding location is conducted through the busbar material, which serves as a thermal conductor and intermediary structure, transferring heat away from the battery terminals and cells efficiently.
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
This design effectively reduces heat generation and increases power capacity by allowing current to flow along the edge of the electrode terminals, while minimizing the module's overall height, thus enhancing scalability and serviceability.
Implementation Method 1
a portion where the electrode terminal is welded to the busbar
Data Source
AI summary
A battery module includes a plurality of battery cells with protruding terminal parts that include a first electrode terminal and a second electrode terminal. A frame part accommodates the plurality of battery cells, and busbars are electrically connected to the terminal parts of the plurality of battery cells. Each of the busbars is formed with insertion holes into which the terminal parts are inserted.