Battery Module Busbar Geometry to Prevent Electrode Lead Breakage
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Solution Overview
Problem
Conventional battery modules face issues with breakage of electrode tabs and connecting portions due to tensile forces during the bending process of electrode leads, which can lead to internal short circuits and safety risks.
Innovation Solution
A novel connection configuration for electrode leads and busbars is introduced, where the busbar includes a first and second portion at a specific angle, allowing electrode leads to be joined without bending, and a bead portion is formed to facilitate stable welding, eliminating the need for bending and cutting processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrode leads are bent to connect to busbar, then electrical connection is achieved, but tensile force causes breakage of electrode tabs or connecting portions
Solution Approach 1:
Instead of bending the electrode lead to match the busbar, the busbar is designed with a bent portion that matches the electrode lead's natural straight configuration. This inverts the deformation action from the electrode lead to the busbar, eliminating tensile force on the electrode lead and preventing breakage while maintaining reliable electrical connection.
2Ease of manufacture
If electrode leads are bent and cut to fit busbar, then connection is achieved, but production complexity and costs increase
Solution Approach 1:
The busbar is pre-formed with a bent portion during manufacturing to match the electrode lead's configuration. This preliminary action eliminates the need for subsequent bending and cutting operations on the electrode lead, simplifying the production process and reducing complexity while maintaining ease of connection.
3Reliability
If electrode leads are bent during assembly, then electrical connection is established, but productivity decreases due to additional processes
Solution Approach 1:
The busbar is pre-formed with the appropriate bend during manufacturing, eliminating the need for bending operations during assembly. This reduces the number of assembly steps and improves productivity while ensuring reliable electrical connection through the pre-configured geometry.
4Device complexity
If conventional busbar design is used, then simple structure is maintained, but electrode tab breakage occurs due to tensile force
Solution Approach 1:
The busbar design is inverted from a straight configuration to one with a bent portion that accommodates the electrode lead's natural position. This design inversion eliminates the need to bend the electrode lead, preventing tensile force-induced breakage of electrode tabs while maintaining structural simplicity.
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 configuration prevents breakage of electrode tabs and connecting portions, reduces production costs, and enhances productivity by eliminating unnecessary processes, while ensuring stable electrical connections.
Implementation Method 1
the electrode lead is joined to the second portion
Data Source
AI summary
A battery module includes: a battery cell stack in which battery cells are stacked along a first direction; and at least one busbar located on one side or both sides of the battery cell stack. An electrode lead protrudes from the battery cell along a second direction perpendicular to the first direction. The busbar includes a first portion, and a second portion that extends from the first portion at a certain angle with respect to one surface of the first portion, and the electrode lead is joined to the second portion.