Battery Module Busbar Insulation Against Electrolyte Short Circuits
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Solution Overview
Problem
Conventional battery modules face issues with short circuits between busbars due to moisture and electrolyte leakage, leading to potential fires and safety hazards.
Innovation Solution
A battery module structure featuring insulating covers that shield the space between busbars, coupled to the busbar frame using adhesives or fastening members, to prevent short circuits by blocking the flow of electrolyte and moisture, and maintaining a separation distance between busbars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If busbars are arranged closely to increase energy density, then productivity and space utilization are improved, but the risk of short circuit between busbars increases due to moisture and electrolyte leakage
Solution Approach 1:
An insulating cover made of insulating material is introduced as an intermediary element between adjacent busbars. This cover physically separates the busbars and prevents direct contact, thereby blocking the short circuit path while allowing the busbars to maintain close spacing for high energy density.
Solution Approach 2:
The insulating cover is installed in advance on the busbar frame before the battery cells are assembled. This preliminary protective measure prevents moisture and electrolyte from reaching the busbars, countering the potential harmful effects before they can occur during battery operation.
2Reliability
If partition walls are added between busbars to prevent short circuits, then reliability is improved, but device complexity increases
Solution Approach 1:
The partition wall function is extracted from the busbar frame structure and implemented as a separate, movable insulating cover. This allows the insulating cover to be independently positioned and removed if needed, simplifying the overall structure while maintaining the short circuit prevention function.
Solution Approach 2:
The insulating cover is designed as a thin-walled structure made of insulating material that can flexibly adapt to the busbar arrangement. This thin-film approach provides effective insulation without adding significant structural complexity or volume to the battery module.
3Reliability
If insulating covers are added to prevent short circuits, then reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The insulating covers are integrated with the busbar frame structure, forming a unified assembly that is pre-installed on the busbar frame before battery cell assembly. This merging of functions reduces the number of separate assembly steps and simplifies the overall manufacturing process.
Solution Approach 2:
The insulating covers are pre-installed on the busbar frame in advance of battery cell assembly. This preliminary action ensures that the protective structure is already in place before the battery cells are introduced, simplifying the assembly sequence and reducing manufacturing complexity.
Data Source
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AI summary
A battery module according to one embodiment of the present disclosure includes a battery cell stack in which a plurality of battery cells are stacked, a busbar frame that is positioned in at least one end part of the battery cell stack, a module frame that houses a cell block including the battery cell stack and the busbar frame, an end plate that covers the front and rear surfaces of the cell block and is coupled to the module frame, and an insulating cover that is positioned between the end plate and the battery cell stack, wherein the insulating cover comprises a first insulating cover and a second insulating cover, and wherein the first insulating cover covers the first busbar coupled to the busbar frame, and the second insulating cover covers the second busbar coupled to the busbar frame.