Battery Module Lead Layout for Narrower Busbar Connections
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Solution Overview
Problem
Conventional battery modules suffer from low space utilization due to the large width of busbars that overlap multiple electrode leads, leading to inefficient use of space and increased weight and manufacturing costs.
Innovation Solution
A battery module design where the busbar is coupled to only one electrode lead, minimizing overlap with other leads, and the electrode leads are arranged to reduce bend angles and overlap, with cell cases configured to optimize space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the busbar is configured to overlap all the overlapping coupled parts of the plurality of electrode leads, then electrical connection of battery cells is achieved, but space utilization deteriorates due to large width of the busbar
Solution Approach 1:
The patent transitions from a two-dimensional overlapping arrangement (busbar covering all overlapping leads in plan view) to a three-dimensional stacked arrangement (busbar coupled to one lead, other leads coupled sequentially above/below). This dimensional change allows electrical connection of all leads while minimizing the horizontal space occupied by the busbar, thereby improving space utilization within the battery module.
Solution Approach 2:
The patent segments the electrical connection process into multiple sequential coupling points along the electrode leads, rather than requiring all leads to overlap at a single point beneath the busbar. This segmentation allows the busbar to be narrower and positioned at one location, while other leads are connected at different positions along their length, reducing the busbar's required width and improving overall space utilization.
2Ease of manufacture
If the busbar width is increased to cover all overlapping electrode leads, then manufacturing simplicity is maintained, but weight increases
Solution Approach 1:
By arranging electrode leads in a three-dimensional stacked configuration rather than requiring all leads to overlap in a single two-dimensional plane, the busbar can be narrower and thus lighter, while still providing electrical connection to all leads through sequential coupling points at different vertical positions.
Solution Approach 2:
The patent changes the geometric parameters of the electrode leads, specifically their lengths and positions, to enable sequential coupling. This allows the busbar to be optimized for minimal weight while still achieving the required electrical connection function across all battery cells.
3Stability of the object's composition
If the busbar width is increased to overlap multiple electrode leads, then structural stability is improved, but space utilization deteriorates
Solution Approach 1:
The patent segments the electrical and mechanical connection into multiple discrete coupling points along the electrode leads rather than relying on a single large overlapping region. This segmentation provides distributed structural support that maintains stability while allowing each coupling point to be more compact, thereby improving overall space utilization.
Solution Approach 2:
By distributing the coupling points in the vertical dimension (stacking leads above and below each other) rather than requiring horizontal overlap, the structure achieves stability through distributed connections in three dimensions, allowing for a narrower busbar and better space utilization in the horizontal plane.
Data Source
AI summary
There are provided a battery module with improved space utilization and a battery pack and a vehicle including the same. The battery module according to an aspect of the present disclosure includes: a plurality of battery cells, each including an electrode assembly and a cell case accommodating the electrode assembly; a plurality of electrode leads, each connected to the electrode assembly of each of the plurality of battery cells and extending to a predetermined length from the cell case, and coupled to each other such that each end portion overlaps an end portion of another electrode lead in a sequential order; and a busbar coupled to any one of the overlapping coupled electrode leads.