Battery Module Busbar Layout for Same-Side Output and Venting
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Solution Overview
Problem
Existing battery modules with output electrodes at opposite ends complicate connection lines, increase space occupancy, and affect energy density, while also posing safety risks due to heat accumulation and potential short circuits.
Innovation Solution
A battery module design where busbar components extend slantly to allow same-side output and heat dissipation, featuring through holes above explosion-proof valves to facilitate gas exhaustion and prevent overheating, with fusing regions of varying widths to quickly cut off circuits in case of short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If output electrodes are disposed at opposite ends of the battery module, then electrical connection between batteries is implemented, but connection lines become complicated and space occupancy increases
Solution Approach 1:
The busbar component merges multiple functions: it serves as both the electrical connection element and the exhaust channel structure. The first busbar component connects multiple batteries electrically while simultaneously providing a pathway for gas exhaust through its integrated through hole, eliminating the need for separate connection lines and exhaust structures.
Solution Approach 2:
The busbar component is designed to perform multiple functions: electrical connection between batteries, structural support, and gas exhaust channel. This multi-functional design simplifies the overall structure by replacing what would traditionally require separate components for each function.
2Reliability
If output electrodes are disposed at opposite ends, then electrical connection is achieved, but space occupied by connection lines increases
Solution Approach 1:
The busbar component merges electrical connection and exhaust functions into a single structure that spans across the battery module. This integration eliminates the need for separate connection lines running across the module, thereby reducing the space occupied by connection infrastructure.
3Reliability
If through hole is disposed above explosion-proof valve, then gas exhaustion is facilitated, but heat dissipation space is reduced
Solution Approach 1:
The through hole extracts a portion of the busbar component to create an opening that serves dual purposes: allowing gas to escape from the explosion-proof valve and providing a pathway for heat dissipation. This extraction creates a functional void that benefits both gas exhaustion and thermal management.
Solution Approach 2:
The through hole in the busbar component serves multiple functions simultaneously: it acts as an exhaust channel for gas pressure relief, a heat dissipation pathway, and a structural element that maintains busbar integrity while enabling thermal and pressure management.
4Reliability
If fusing regions of varying widths are created, then circuit breaking protection is enhanced, but manufacturing complexity increases
Solution Approach 1:
The busbar component features local quality variations through fusing regions of different widths. These varying widths create specific electrical resistance characteristics at different locations, enabling controlled circuit breaking at predetermined points while maintaining uniform manufacturing processes.
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 simplifies connection lines, prevents heat accumulation, reduces safety risks by ensuring timely gas exhaustion, and rapidly cuts off circuits in case of short circuits, enhancing both energy density and safety performance.
Implementation Method 1
when the pressure relief valve acts due to the internal pressure of the battery core, the generated high temperature and high pressure gas or solid fuses the bus bar to realize the circuit breaking protection
Implementation Method 2
the generated high temperature and high pressure gas or solid fuses the bus bar to realize the circuit breaking protection
Data Source
Figure 1~2
Figure 3~4
AI summary
This application provides a battery module and an assembling method thereof. The battery module includes batteries and busbar components. The batteries are plural in number and laid out consecutively along a longitudinal direction. Each battery includes a first electrode terminal and a second electrode terminal. The busbar components are plural in number and connected to the plurality of batteries. The plurality of batteries include a first battery and a second battery. The first electrode terminal of the first battery and the first electrode terminal of the second battery are laid out along the longitudinal direction. The plurality of busbar components include a first busbar component, and the first busbar component includes a first part, a second part, and a third part. The first part is connected to the first electrode terminal of the first battery, the second part is connected to the second electrode terminal of the second battery, and the third part connects the first part and the second part. A through hole is disposed on the third part.