Integrated Bus Bar in Battery Module ICB Housing
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Solution Overview
Problem
Conventional battery modules have complex electric connection structures between secondary batteries and power terminals, requiring multiple laser welding processes, which are time-consuming and complex.
Innovation Solution
A battery module design featuring a cartridge stack with protruding electrode leads, an ICB housing with stepped connections, and a bus bar that connects the electrode leads directly to the power terminal, reducing the number of welding processes and simplifying the structure by embedding the connection parts within the ICB housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional battery module structure with separate ICB housing and module case is used, then electrical connection is achieved, but assembly time increases due to multiple laser welding processes
Solution Approach 1:
The patent merges the ICB housing and module case into a single integrated structure. The bus bar is directly formed as part of the housing structure, eliminating the need for separate components and multiple welding processes. This integration reduces assembly steps while maintaining electrical connection functionality.
Solution Approach 2:
The housing structure serves multiple functions simultaneously: it provides mechanical protection, structural support, and electrical connection through the integrated bus bar. This multi-functionality eliminates the need for separate dedicated electrical connection components, simplifying the overall structure.
2Reliability
If multiple bus bars are used for electrical connection, then reliable electrical connection is achieved, but device complexity increases
Solution Approach 1:
Multiple bus bar functions are merged into a single integrated bus bar structure that is formed as part of the housing. This single structure provides all necessary electrical connections that would otherwise require multiple separate bus bars, reducing complexity while maintaining reliability.
Solution Approach 2:
The integrated bus bar structure performs multiple electrical connection functions simultaneously, connecting different battery modules and providing current pathways that would traditionally require separate dedicated bus bars for each connection point.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design reduces the time required for assembly by minimizing the number of laser welding steps and simplifies the electric connection structure, using fewer bus bars and embedding connections within the ICB housing.
Implementation Method 1
a bus bar electrically connecting the electrode lead with the power terminal
Implementation Method 2
laser welding processing including two processes of a first welding process of laser-welding the electrode lead of the secondary batteries with the first bus bar
Data Source
AI summary
The present disclosure relates to a battery module including a cartridge stack including a plurality of secondary batteries which each include an electrode lead and a plurality of cartridges which each accommodate at least one of the plurality of secondary batteries such that at least a portion of the electrode lead protrudes outwardly, and which are stacked in a plurality of stages, and an ICB housing which includes a stepped connection end, a power terminal installed fixedly to the connection end, and a bus bar electrically connecting the electrode lead with the power terminal, and which is mounted on a surface of the cartridge stack, in which the bus bar includes a first connection part which is provided in opposition to the power terminal, having the connection end therebetween, and is connected with the electrode lead, a second connection part which is provided in opposition to the first connection part, having the connection end therebetween, and is connected with the power terminal, and a connection part which connects the first connection part with the second connection part and is embedded in the connection end.