Battery Module Lead Joint Assembly for Busbar-Free Sensing

Solution Overview

Problem

Conventional battery modules face challenges in improving productivity due to complex HV and LV connection structures, which are separate and require additional components like busbars and busbar frames, leading to increased complexity and reduced compactness.

Innovation Solution

A battery module design that integrates electrode lead joints and a sensing assembly within an insulating cover, allowing for simultaneous HV and LV connections without the need for busbars, and includes a method of manufacturing that stacks battery cells with bent electrode leads and a sensing assembly for efficient voltage information transmission.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate busbars and busbar frames are used for HV and LV connections, then connection reliability is improved, but device complexity and manufacturing complexity increase

Engineering Contradiction:

Improveconnection reliabilityVSAvoidconnection structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the HV connection function (busbar) and LV connection function (sensing assembly) into a single integrated connection structure. The connection structure includes a connection terminal with a first connection portion for HV connection and a second connection portion for LV connection, eliminating the need for separate busbars and busbar frames while maintaining both high-voltage and low-voltage connectivity functions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connection structure serves multiple functions simultaneously: it provides both high-voltage power transmission and low-voltage sensing connections through its different connection portions. The insulating cover also serves dual purposes by providing both electrical insulation and structural support for the entire connection assembly.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If separate busbars and busbar frames are used for HV and LV connections, then connection reliability is improved, but ease of manufacture deteriorates

Engineering Contradiction:

Improveconnection reliabilityVSAvoidmanufacturing ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines the HV connection function (busbar) and LV connection function (sensing assembly) into a single integrated connection structure. The connection structure includes a connection terminal with a first connection portion for HV connection and a second connection portion for LV connection, eliminating the need for separate busbars and busbar frames while maintaining both high-voltage and low-voltage connectivity functions.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If busbars and busbar frames are used, then connection functionality is improved, but productivity deteriorates

Engineering Contradiction:

Improveconnection functionalityVSAvoidmanufacturing productivity

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent combines the HV connection function (busbar) and LV connection function (sensing assembly) into a single integrated connection structure. The connection structure includes a connection terminal with a first connection portion for HV connection and a second connection portion for LV connection, eliminating the need for separate busbars and busbar frames while maintaining both high-voltage and low-voltage connectivity functions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The insulating cover is designed with pre-formed recesses that accommodate the connection terminal and sensing assembly, allowing for preliminary positioning and alignment. This preliminary structuring of the insulating cover facilitates easier assembly and improves manufacturing productivity by reducing the complexity of alignment operations during final assembly.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20240014526A1Battery Module, Battery Pack Including the Same and Manufacturing Method of the Same

Publication Date: 2024.01.11 LG ENERGY SOLUTION LTD

AI summary

A battery module according to one embodiment of the present disclosure includes a battery cell stack in which a plurality of battery cells including electrode leads are stacked; and a sensing assembly for transmitting voltage information of the battery cell. The sensing assembly includes a connector, a connection member for connecting the connector and the electrode lead, and a joining member located at one end of the connection member and joined to the electrode lead. At least two of the electrode leads are bent and joined to form an electrode lead joint body, and the joining member is joined to the electrode lead joint body.