Battery Module Busbar Routing to Cut Heat Spread and Thickness
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Solution Overview
Problem
Conventional battery modules face issues with increased thickness, interference noise, exposure to flames during thermal runaway, and potential explosions due to the long electrical connection passages of busbars, which also act as heat diffusion paths.
Innovation Solution
The battery module design alternately stacks positive and negative electrodes at the ends of battery cells, with module busbars connected to lead tabs, and includes an inner plate for electrical connection between battery cells and end plates, minimizing the length of pack busbars and preventing short circuits by positioning them below the battery modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the busbar is disposed over the battery packs to connect battery packs, then electrical connection is achieved, but the thickness of the battery increases
Solution Approach 1:
The busbar connection path is moved from a vertical arrangement (over the battery packs) to a horizontal arrangement (along the bottom surface), changing the spatial dimension of the connection path. This allows electrical connection while reducing the vertical thickness of the battery assembly.
2Reliability
If the busbar is disposed over the battery packs, then electrical connection is achieved, but interference noise is generated due to vibrations
Solution Approach 1:
The busbar is extracted from its position over the battery packs and relocated to the bottom surface. This separation removes the source of vibration-induced interference noise from the vicinity of the battery cells, eliminating the harmful acoustic and electromagnetic interference while preserving electrical connection functionality.
3Reliability
If the busbar is disposed over the battery packs, then electrical connection is achieved, but the busbar is directly exposed to flame during thermal runaway
Solution Approach 1:
The busbar is extracted from the vulnerable position over the battery packs and relocated to the bottom surface. This spatial separation ensures that during thermal runaway events, the busbar is not directly exposed to flames and heat rising from the battery cells, preventing catastrophic failure of the electrical connection system.
4Reliability
If the busbar area is increased for connection, then electrical connection is achieved, but the busbar functions as a heat diffusion passage between modules
Solution Approach 1:
The busbar is relocated from a position where it would create large heat diffusion paths between modules to a position along the bottom surface. This reduces the busbar's role as a thermal conduit, minimizing unwanted heat transfer between battery modules while maintaining electrical connectivity.
5Weight of moving object
If the pack busbar length is reduced, then weight and material cost are reduced, but electrical connection between battery packs must be maintained
Solution Approach 1:
The busbar connection geometry is redesigned by changing from a vertical overhead arrangement to a horizontal bottom-surface arrangement. This dimensional change enables shorter busbar lengths and reduced material usage while maintaining effective electrical connection between battery packs through optimized routing along the bottom surface.
Data Source
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AI summary
A battery module according to one embodiment of the present invention may include battery cells of which positive electrodes and negative electrodes which are formed at one end portions thereof are alternately stacked in a stacking direction, a pair of end plates coupled to both side ends of the stacked battery cells, and module busbars electrically connected to lead tabs provided on the battery cells, wherein, among the battery cells, battery cells disposed at both side ends of the battery module are disposed so that front ends and rear ends have the same electrode.