Battery Module Bus Bar Layout for Swelling-Tolerant Electrode Leads
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Solution Overview
Problem
Conventional battery modules face issues with electrode leads separating from bus bar units due to swelling, leading to potential short circuits and increased risk of explosion or fire.
Innovation Solution
The electrode leads of battery cells are bent at least once and have varying lengths and bends to accommodate swelling, with outermost leads being the longest and most bent, connected via a bus bar unit with a frame and connection bus bars to maintain contact during inflation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a battery module is designed to accommodate 96 battery cells with complex internal structures including current collectors, tabs, and connection bars, then the electrical connectivity and capacity are improved, but the manufacturing complexity and assembly difficulty increase significantly
Solution Approach 1:
The battery module is divided into multiple trays, with each tray holding a specific number of battery cells (e.g., 24 cells per tray for lithium iron phosphate, or 48 cells per tray for ternary batteries). This segmentation allows the complex 96-cell module to be assembled from smaller, more manageable tray units, reducing assembly difficulty while maintaining high capacity.
Solution Approach 2:
Connection bars serve as intermediary components that facilitate electrical connections between multiple battery cells and tabs. These connection bars simplify the wiring complexity by providing centralized connection points, reducing the number of direct tab-to-tab connections needed while maintaining electrical integrity across all 96 cells.
2Stability of the object's composition
If battery cells are arranged in a fixed rigid structure within the module, then structural stability is improved, but adaptability to different battery cell types and future modifications is reduced
Solution Approach 1:
The module employs adjustable positioning structures and flexible fixing mechanisms that allow the same module design to accommodate different battery cell types (e.g., lithium iron phosphate with 24 cells per tray, or ternary batteries with 48 cells per tray). The positioning structures can be adjusted or reconfigured to match different cell dimensions and arrangements, providing both stability and adaptability.
3Productivity
If traditional battery module assembly methods are used without automated positioning, then manufacturing flexibility is maintained, but assembly precision and production efficiency decrease
Solution Approach 1:
The module incorporates self-positioning structures such as positioning ribs, guide slots, and snap-fit mechanisms that automatically align and secure battery cells during assembly. These features enable workers or automated systems to quickly install cells without requiring complex external positioning equipment, improving assembly efficiency while keeping the positioning mechanism integrated and relatively simple.
Data Source
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AI summary
A battery module includes: a plurality of battery cells stacked on one another; and a bus bar unit electrically connected to electrode leads of the plurality of battery cells, wherein the electrode leads of the plurality of battery cells are bent at least once to secure a predetermined length and are unbent at least partially due to inflation caused by swelling of the plurality of battery cells.