Battery Module Frame Assembly for Busbar-Free Cell Connections
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Solution Overview
Problem
Existing battery module structures with busbars incur high manufacturing costs and reduced energy density due to the weight and material requirements of the busbar connections.
Innovation Solution
A battery module design that eliminates the need for busbars by directly connecting electrode leads through a frame assembly, utilizing a main frame and cover frame with support ribs to stabilize the connections, allowing for direct electrical connections without additional media.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery modules are designed with large dimensions to increase capacity, then the energy storage capacity is improved, but the deformation control difficulty increases and uniformity of deformation becomes harder to maintain
Solution Approach 1:
The battery module employs a multi-layer bracket structure with first brackets and second brackets positioned at different heights, dividing the support function into multiple segments. This segmentation allows each bracket layer to independently manage deformation in specific regions, thereby controlling overall deformation while maintaining large module dimensions for high capacity.
Solution Approach 2:
The bracket structure features different structural characteristics at different locations - first brackets extend in a first direction while second brackets extend in a second direction perpendicular to the first. This local quality variation enables targeted deformation control in different areas of the battery module, addressing the uniformity issue while preserving overall capacity.
2Quantity of substance
If battery modules are designed with large dimensions to increase capacity, then the energy storage capacity is improved, but the heat dissipation efficiency deteriorates
Solution Approach 1:
The bracket structure utilizes three-dimensional spatial arrangement with brackets extending in multiple directions (first direction and second direction perpendicular thereto) and at different heights (first and second levels). This dimensional expansion creates enhanced heat dissipation pathways throughout the volume of the battery module, allowing efficient heat management despite large dimensions required for high capacity.
3Quantity of substance
If battery modules are designed with large dimensions to increase capacity, then the energy storage capacity is improved, but the structural stability deteriorates
Solution Approach 1:
The support structure is segmented into multiple bracket layers at different heights, with each layer providing localized structural reinforcement. This segmented approach maintains structural stability across the large module volume by distributing mechanical loads throughout the structure rather than relying on a single support system.
Solution Approach 2:
The brackets are pre-configured in specific orientations and positions (first brackets extending in first direction, second brackets extending in perpendicular second direction) to proactively counteract expected deformation forces. This preliminary structural arrangement prevents instability before it occurs, maintaining composition stability in large-capacity modules.
Data Source
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AI summary
A battery module according to an embodiment of the present disclosure includes a cell assembly including a plurality of battery cells, and a frame assembly covering at least one side of the cell assembly, and configured to guide direct connection between electrode leads of adjacent battery cells.