Battery Module Bridging Busbar Overlap Insulation
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Solution Overview
Problem
Conventional battery module configurations face limitations in heat dissipation and safety due to electrode connection piece arrangements, which restrict diversity and energy density.
Innovation Solution
A battery module design featuring bridging busbars that partially overlap in an electrical insulation manner, with electrode output connecting pieces and adjacent busbars, allowing for reduced bridging busbar length and improved compactness, enhancing energy density and safety by facilitating efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional electrode connection piece arrangement is used, then the battery module structure is simple, but the heat dissipation performance is poor and safety is compromised
Solution Approach 1:
The connection structure is segmented into multiple functional components: adjacent busbars for connecting neighboring battery units, bridging busbars for spanning across battery units, insulators for electrical isolation, and cooling plates for thermal management. This segmentation allows each component to perform its specific function optimally, improving heat dissipation while maintaining structural organization.
Solution Approach 2:
The design implements nested positioning where bridging busbars are positioned above and below battery units with insulators interposed between them. The insulators extend beyond the busbar edges to provide additional insulation coverage. This nested arrangement optimizes space utilization and enables efficient heat dissipation paths without compromising electrical isolation.
2Adaptability or versatility
If bridging busbars are made longer to connect spaced battery units, then the adaptability of configuration increases, but the energy density decreases
Solution Approach 1:
The busbar system provides flexible configuration adaptability through the combination of adjacent and bridging busbars that can connect battery units at various spacings. The insulator design with extension beyond busbar edges allows for adjustable positioning while maintaining electrical isolation. This dynamic configurability enables diverse battery module layouts without requiring excessively long busbars, thereby preserving energy density.
3Volume of stationary object
If bridging busbars are positioned closer to reduce space, then the compactness improves, but the risk of electrical short circuit increases
Solution Approach 1:
Insulators are introduced as intermediary components positioned between upper and lower bridging busbars. These insulators extend beyond the busbar edges to provide additional insulation coverage and prevent electrical short circuits. The intermediary insulators enable the busbars to be positioned closer together for compactness while maintaining reliable electrical isolation.
4Reliability
If the periphery of insulator extends beyond busbar circumference by 2mm to 6mm, then the insulation reliability improves, but the material usage increases
Solution Approach 1:
The insulator is designed with non-uniform dimensions where the periphery extends beyond the busbar circumference by 2mm to 6mm at critical locations to provide enhanced insulation coverage. This local quality enhancement ensures reliable electrical isolation at the most vulnerable points while avoiding excessive material usage in areas where less insulation is needed, optimizing the balance between insulation reliability and material efficiency.
Data Source
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AI summary
The present disclosure relates to a battery module. The battery module includes a plurality of battery units connected in series; an electrode output connecting piece disposed at an output end of the plurality of battery units; a plurality of bridging busbars, each connecting two battery units spaced by another battery unit or more battery units among the plurality of battery units; and an adjacent busbar connecting adjacent battery units among the plurality of battery units. An electrical connection path is formed in the battery module by the electrode output connecting piece, the bridging busbars and the adjacent busbar. At least two of the plurality of bridging busbars partially overlap and fit one another in an electrical insulation manner as a group. The battery module according to the present disclosure is applicable in diverse situations, and capable of improving safety performance and energy density.