Battery Module Busbar Recess for Compact Nut Fixing
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Solution Overview
Problem
Conventional battery modules have a complex and costly nut-fixing structure, with unnecessary space between the nut and terminal busbar, leading to inefficiencies in space utilization and increased module length, which affects energy density.
Innovation Solution
A battery module design where the terminal busbar has a recessed side surface to accommodate the nut, eliminating the need for a separate nut-fixing structure and allowing for a simpler, more compact nut shape, with the nut inserted into the recessed space, thereby optimizing component arrangement and reducing module length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate nut-fixing structure is manufactured on the end plate, then the nut can be securely fixed, but the device complexity and manufacturing cost increase
Solution Approach 1:
The nut-fixing function is merged with the existing terminal busbar structure by forming a recessed space directly on the terminal busbar. This eliminates the need for a separate nut-fixing structure on the end plate, reducing device complexity while maintaining secure nut fixation through the integrated recessed space.
Solution Approach 2:
The terminal busbar is given multiple functions: it serves both as an electrical connection component and as a structural support for nut fixation. The recessed space formed on the terminal busbar provides the fixation function, making the terminal busbar a multi-functional component that reduces overall device complexity.
2Ease of operation
If the nut is positioned outside the terminal busbar with a separate fixing structure, then the nut can be installed, but unnecessary empty space is created between the nut and terminal busbar
Solution Approach 1:
The nut is nested within the recessed space formed on the terminal busbar. This nesting arrangement eliminates empty space between the nut and terminal busbar, maximizing volume utilization of the battery module while maintaining ease of nut installation through the integrated recessed structure.
3Ease of operation
If the terminal busbar upper end is bent and the nut is positioned on the right side, then the nut can be installed, but an empty space is formed that reduces space utilization
Solution Approach 1:
The nut installation position is merged with the terminal busbar structure by forming a recessed space directly on the terminal busbar. This eliminates the need for separate positioning arrangements and removes empty spaces, thereby improving space utilization and energy density while maintaining ease of nut installation.
Data Source
AI summary
A battery module with improved space utilization of a secondary battery includes a battery cell stack in which a plurality of battery cells are stacked; a busbar frame formed on a front surface or a rear surfaces of the battery cell stack; a terminal busbar formed outside the busbar frame based on the battery cell stack to be electrically connected to an external power source; and an end plate covering the busbar frame, wherein the terminal busbar is formed is formed to have a recessed side surface, and a nut is inserted into a space formed by the recessed side surface and the busbar frame. A battery pack including the battery module is also provided.