Battery Module Busbar Frame Insulation at Lower Frame Boundary
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Solution Overview
Problem
Conventional battery modules face insulation performance issues due to gaps in the boundary area between the central part of the lower frame and the stepped part, which can lead to insufficient insulation between the battery cell and the module frame, especially in high-voltage applications.
Innovation Solution
The battery module incorporates an insulating member extended from the busbar frame's support part toward the module frame's lower surface, covering the boundary line between the central part and the stepped part, and a blocking pad on the lower frame to enhance insulation, using materials like PET, PC, PI, and PA, and an adhesive layer for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating member is attached only to the stepped part of the lower frame, then the manufacturing process is simple, but the insulation performance between the battery cell and the module frame is insufficient at the boundary part
Solution Approach 1:
The insulating member is extended from a two-dimensional attachment on the stepped part to a three-dimensional configuration that covers the boundary part and reaches the central part of the lower frame. This dimensional extension ensures continuous insulation coverage across all critical areas where the battery cell may contact the module frame, resolving the insulation deficiency at the boundary part while maintaining manufacturing simplicity.
Solution Approach 2:
The insulating member is pre-configured with an extended structure that anticipates potential contact points between the battery cell and the module frame. By extending the insulating member to cover the boundary part and central part in advance, the design proactively prevents insulation failures before they occur, rather than reacting to contact issues after assembly.
2Reliability
If the insulating member is extended to cover the boundary line, then insulation performance is improved, but the manufacturing complexity increases
Solution Approach 1:
The insulating member integrates multiple functions into a single component: it provides insulation at the stepped part, extends coverage to the boundary part, and reaches the central part of the lower frame. This merging of multiple insulation zones into one unified component simplifies manufacturing by reducing the number of separate insulating parts and assembly steps, while achieving comprehensive insulation coverage.
3Reliability
If a blocking pad is added adjacent to the stepped part, then insulation and mechanical protection are enhanced, but the device complexity and manufacturing steps increase
Solution Approach 1:
The blocking pad is designed to perform multiple functions simultaneously: it provides electrical insulation between the battery cell and the module frame, and acts as a mechanical buffer to absorb impact forces. This multi-functionality allows a single component to address both insulation and protection requirements, reducing the need for separate components and minimizing the increase in device complexity.
Data Source
AI summary
A battery module includes: a battery cell stack in which a plurality of battery cells are stacked; a busbar frame connected to the front and rear surfaces of the battery cell stack, respectively; and a module frame that houses the battery cell stack on which the busbar frame is mounted. The busbar frame has a support part that wraps the end part of the battery cell, and wherein the battery module further comprises an insulating member that is extended from the lower surface of the support part toward the outside of the support part.