Battery Module Lead Frame for Busbar-Free Cell Connections
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Solution Overview
Problem
Conventional battery modules require complex manufacturing processes due to the need for multiple components for HV and LV connections, which complicates the manufacturing process and increases costs.
Innovation Solution
A battery module design that eliminates the busbar by using a lead frame with protruded or recessed support parts for electrode lead assemblies, allowing direct joining of electrode leads and integrating sensing assemblies for simultaneous HV and LV connections, reducing the need for separate busbars and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If busbar and busbar frame are used for connection between battery cells, then electrical connection is achieved, but device complexity increases and manufacturing process becomes complicated
Solution Approach 1:
The patent merges the busbar frame and busbar into a single integrated lead frame structure. The lead frame includes support parts that directly hold electrode leads without requiring separate busbar components. This integration eliminates the need for complex assembly processes and reduces the number of parts while maintaining reliable electrical connection between battery cells.
Solution Approach 2:
The lead frame serves multiple functions simultaneously: it provides structural support for electrode leads, establishes electrical connections between cells, and integrates sensing assembly mounting. This multi-functional design replaces the traditional separate busbar and busbar frame system, simplifying the overall device structure and manufacturing process.
2Reliability
If busbar and busbar frame are used for connection, then electrical connection is achieved, but manufacturing cost increases
Solution Approach 1:
By combining the busbar frame and busbar into a single lead frame component, the patent reduces part count and assembly steps. This integration lowers manufacturing costs through reduced material usage, simplified production processes, and decreased assembly time while maintaining reliable electrical connection functionality.
3Reliability
If separate busbar and busbar frame are used, then HV connection is achieved, but space utilization decreases
Solution Approach 1:
The integration of busbar frame and busbar into a compact lead frame structure reduces the overall volume occupied by connection components. The lead frame's support parts are strategically positioned to provide HV connection functionality while minimizing space consumption, thereby improving space utilization in the battery module.
Data Source
AI summary
A battery module according to an embodiment of the present disclosure includes a battery cell stack in which a plurality of battery cells including an electrode lead are stacked; and a lead frame located on one side of the battery cell stack. A first electrode lead protruding from a first battery cell among the plurality of battery cells and a second electrode lead protruding from a second battery cell among the plurality of battery cells are bent after passing through a slit formed in the lead frame and then overlapped to form an electrode lead assembly. In the electrode lead assembly, at least a part of the first electrode lead and at least a part of the second electrode lead are joined to each other. The lead frame includes a first support part on which the electrode lead assembly is located. The first support part has a shape that is protruded in a direction in which the electrode lead assembly is located or a shape that is recessed in a direction opposite to the direction in which the electrode lead assembly is located. At least a part of the electrode lead assembly is in close contact with one surface of the first support part.