Battery Module Lead Offset Layout for Higher Energy Density
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Solution Overview
Problem
Conventional battery modules have a structure where electrode leads are drawn from the center, leading to increased height or length and reduced energy density due to insufficient space for components like outer terminals, necessitating a method to improve energy density without significant changes to the manufacturing process.
Innovation Solution
A battery module design where electrode leads are biased downward, allowing for the placement of outer terminals and other components in the space above, utilizing a bus bar frame assembly, FPCB assembly, and an upper cover to minimize volume increase and enhance energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If electrode leads are drawn from the center portion of the battery cell, then the battery module structure is simple, but the overall height or length increases and energy density decreases
Solution Approach 1:
The patent applies asymmetry by positioning the electrode leads at a biased location rather than the center of the battery cell. This asymmetric arrangement creates unused space above the electrode leads that can be utilized for mounting components, thereby reducing the overall height or length of the battery module while maintaining structural simplicity and improving energy density.
Solution Approach 2:
The patent utilizes the vertical dimension by mounting components above the electrode leads in the created space. This dimensional approach allows efficient use of available space, reducing the footprint in other dimensions and improving overall energy density without complicating the module structure.
2Ease of manufacture
If electrode leads are drawn from the center portion of the battery cell, then the manufacturing process remains conventional, but insufficient space is created for mounting components
Solution Approach 1:
By drawing electrode leads from a biased location rather than the center, the patent creates additional mounting space above the leads while maintaining compatibility with conventional manufacturing processes. This asymmetric configuration allows components to be mounted in the previously unused space without requiring significant manufacturing changes.
3Adaptability or versatility
If the overall height or length of the battery module is increased to accommodate components, then components can be properly mounted, but energy density is reduced
Solution Approach 1:
The patent resolves this contradiction by utilizing the vertical dimension above the electrode leads for component mounting. This approach allows components to be properly accommodated without increasing the overall height or length of the battery module in a way that would reduce energy density, as the space is efficiently used in the existing volume.
Solution Approach 2:
The asymmetric positioning of electrode leads creates dedicated space above them for component mounting, allowing the battery module to accommodate components without requiring proportional increases in overall dimensions that would compromise energy density.
Data Source
AI summary
A battery module includes a cell stack formed by stacking a plurality of battery cells; a bus bar frame assembly; and an outer terminal. The bus bar frame assembly includes a bus bar frame and a plurality of bus bars fixed on the bus bar frame and electrically connected to the battery cells, the bus bar frame being configured to cover first and second opposing longitudinal ends of the cell stack, and the outer terminal is connected to the plurality of bus bars. A pair of electrode leads of each of the battery cells are formed at locations offset downwardly from a center of the cell stack in a height direction, and the outer terminal is disposed in the space formed above the electrode leads due to the offsetting of the electrode leads.