Battery Module Bus Bar Layout for Ultra-Long Cell Cooling
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Solution Overview
Problem
Long and ultra-long battery cells face issues with increased internal resistance, temperature disparities leading to performance deterioration, and structural instability due to their extended length and weight, which hinder their commercialization.
Innovation Solution
A battery module structure that includes end-side and transverse bus bar assemblies to connect electrode tabs in series and parallel configurations, combined with heat radiation plates and cooling systems to manage internal resistance, temperature, and structural stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the battery cell width is increased to 600 mm or more (ultra-long battery cell), then the energy density and spatial utilization are improved, but the cell internal resistance increases due to the large length between electrode tabs
Solution Approach 1:
The battery cell is segmented into multiple electrode tabs positioned at different locations along the width, rather than having a single pair of tabs at opposite ends. This segmentation reduces the current path length and internal resistance while maintaining the ultra-long width for high energy density
Solution Approach 2:
The electrode tabs are arranged in a multi-dimensional configuration across the width of the battery cell, transitioning from a one-dimensional linear arrangement to a two-dimensional distributed arrangement, which reduces the effective current path length despite the increased cell width
2Area of stationary object
If the battery cell width is increased to 600 mm or more (ultra-long battery cell), then the spatial restriction is reduced, but the temperature difference between regions increases causing performance deterioration
Solution Approach 1:
Multiple electrode tabs are distributed at different locations across the width of the battery cell, creating local current collection points that reduce localized heat generation and temperature differences across the cell structure
Solution Approach 2:
The large width that initially causes temperature differences is converted into a benefit by strategically positioning multiple electrode tabs to create additional heat dissipation pathways and reduce thermal gradients across the cell
3Quantity of substance
If the battery cell width is increased to 600 mm or more (ultra-long battery cell), then the energy capacity is increased, but the cell structure becomes unstable and prone to bending under its own weight
Solution Approach 1:
The battery cell structure is segmented with multiple internal support elements and reinforced partitions that divide the large-width cell into smaller structural bays, preventing bending while maintaining the overall ultra-long width for high energy capacity
Solution Approach 2:
The battery cell employs composite material structures with reinforced separators and support frames that provide mechanical strength and rigidity to the ultra-long cell, preventing bending under its own weight while maintaining the large width for high energy density
Data Source
AI summary
A battery module including: a battery stack of battery cells having opposite ends to which a plurality of electrode tabs are connected; end-side bus bar assemblies formed at opposite ends of the battery stack, respectively, and electrically connecting the electrode tabs of the battery cells; and a case accommodating the battery stack and the end-side bus bar assemblies.