Battery Module Busbar Frame for Electrode Lead Separation
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Solution Overview
Problem
Conventional battery modules face issues where electrode leads can come into contact with the edge of the cell terrace, leading to potential corrosion and reduced battery life, particularly as the number of cells increases, and existing solutions like insulating tape are not always effective or durable.
Innovation Solution
A battery module design featuring a busbar frame with a partition wall and path guiders that separates adjacent electrode leads, preventing contact with the cell terrace edges by maintaining a controlled interval and using a bending structure to manage lead placement and connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of battery cells and electrode leads increases, then the battery capacity and electrical output increase, but the electrode leads become more compact and may contact the cell terrace edges
Solution Approach 1:
The busbar frame is divided into multiple partition walls that create separate regions for adjacent electrode leads. Each partition wall acts as an independent barrier, segmenting the space between cell terraces and preventing electrode leads from contacting the cell terrace edges even as the number of cells increases.
Solution Approach 2:
Partition walls are introduced as intermediary structures between the electrode leads and cell terrace edges. These partition walls serve as mediating elements that physically separate the electrode leads from the cell terraces, preventing direct contact while allowing the electrode leads to maintain their electrical connection functions.
2Object-affected harmful factors
If insulating tape is attached to prevent contact between electrode lead and cell terrace edge, then contact prevention is achieved, but additional fees and processes are required and the adhesive force is not permanently maintained
Solution Approach 1:
The partition walls are integrated directly into the busbar frame structure, merging the insulation function with the existing structural component. This eliminates the need for separate insulating tape attachments while maintaining the contact prevention function, thereby reducing device complexity and eliminating additional manufacturing processes.
Solution Approach 2:
The busbar frame structure itself provides the insulation function through its partition walls, making the structure self-sufficient for contact prevention. The partition walls are inherently part of the busbar frame design, eliminating the need for external insulating materials and their associated attachment processes.
3Quantity of substance
If the busbar frame structure is designed to accommodate more electrode leads, then the battery capacity increases, but the interval between adjacent cell terraces decreases and contact risk increases
Solution Approach 1:
Multiple partition walls are strategically positioned within the busbar frame to create numerous smaller compartments. This segmentation allows the busbar frame to accommodate more electrode leads by providing dedicated spaces for each lead, effectively managing the reduced interval between cell terraces without increasing contact risk.
Solution Approach 2:
The partition walls extend in the vertical dimension within the busbar frame, creating three-dimensional separation zones. This dimensional approach allows efficient use of space to accommodate more electrode leads while maintaining adequate separation distances through vertical partitioning rather than solely relying on horizontal spacing.
Data Source
Figure 1~2a
Figure 2b~3
Figure 4~5
AI summary
A battery module according to an exemplary embodiment of the present disclosure includes: a battery cell stack in which a plurality of battery cells are stacked, a busbar frame connected to the battery cell stack, cell terraces each protruding from battery cells adjacent to each other among the battery cells included in the battery cell stack, electrode leads each protruding from the cell terraces, and a partition wall which is disposed between electrode leads adjacent to each other among the electrode leads and is formed on the busbar frame, wherein the partition wall includes an outermost partition wall located between a first cell terrace protruding from the outermost battery cell and a second cell terrace protruding from the battery cell immediately adjacent to the outermost battery cell among the battery cells included in the battery cell stack.