Battery Module Electrode Lead Layout for Narrower Busbars
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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 inefficiencies in space usage and increased weight and manufacturing costs.
Innovation Solution
A battery module design where the busbar is coupled to only one electrode lead, minimizing overlaps and reducing the size of the busbar, while electrode leads are arranged to minimize bends and overlaps, allowing for improved stacking and 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 is ensured, but the width of the busbar becomes too large resulting in low space utilization
Solution Approach 1:
The patent extracts the busbar from overlapping multiple electrode leads and repositions it to overlap only a single electrode lead. This extraction principle reduces the busbar width while maintaining electrical connection functionality through the sequential overlapping structure of the electrode leads themselves.
Solution Approach 2:
The patent utilizes the width dimension of the battery module by arranging electrode leads to overlap sequentially in the width direction. This dimensional arrangement allows the busbar to be narrower while still achieving comprehensive electrical connection through the stacked configuration of battery cells and their corresponding electrode leads.
2Area of stationary object
If the busbar width is reduced to improve space utilization, then manufacturing costs decrease, but the coupling points may become less stable
Solution Approach 1:
The patent segments the electrical connection function across multiple overlapping electrode leads rather than relying on a single wide busbar. Each electrode lead forms its own coupling point with the busbar, distributing the connection stability requirement across multiple localized interfaces rather than one large interface.
Solution Approach 2:
The patent implements a nested structure where electrode leads overlap sequentially (first lead overlapped by second lead overlapped by third lead, etc.), creating a stacked configuration. This nesting allows the reduced-width busbar to maintain stable coupling at each overlap level while improving overall space utilization.
3Reliability
If multiple electrode leads are overlapped and coupled to the busbar, then electrical connection is achieved, but the number of bends in electrode leads increases
Solution Approach 1:
The patent merges the electrical connection function into a single busbar interface that couples to one electrode lead, while the other electrode leads connect through sequential overlapping. This combining approach reduces the total number of bends required compared to having the busbar interface with multiple separate connection points.
Data Source
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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 with each end portion overlapping in a sequential order, and a busbar coupled to any one of the overlapping coupled electrode leads.