Battery Module Internal Connection Member Design
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Solution Overview
Problem
The use of external busbars for connecting battery modules in battery packs leads to a decrease in volume energy density, especially when high currents are involved, as they need to be thickened, which increases the overall size and potentially causes short circuits due to wear or deformation.
Innovation Solution
A battery module design featuring flat plate batteries stacked with a plate-shaped connection member having insulation on its sides, where the connection terminals are positioned on opposite sides without insulation, allowing for internal connection between adjacent modules, eliminating the need for external busbars and enhancing safety by reducing the likelihood of short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external busbars are used to connect battery modules, then electrical connection between modules is achieved, but volume energy density decreases due to the need for thick busbars to handle high currents
Solution Approach 1:
The connection member is merged with the battery module structure, integrating the electrical connection function into the module itself rather than using separate external busbars. This integration eliminates the need for additional external connection components and optimizes space utilization within the battery pack.
Solution Approach 2:
The connection member extends in the stacking direction (vertical dimension) rather than horizontally across modules. By positioning terminals at opposite ends of the connection member in the stacking direction, electrical connection is achieved through vertical integration, saving horizontal space and improving volume energy density.
2Power
If thick busbars are used for high current applications, then current carrying capacity is sufficient, but the overall size of the battery pack increases
Solution Approach 1:
The connection member is segmented into distinct functional zones: insulation members covering side surfaces for electrical isolation, and terminal regions at opposite ends for electrical connection. This segmentation allows optimized current paths through the terminals while maintaining compact overall dimensions.
Solution Approach 2:
Different regions of the connection member have different properties: insulation members provide electrical isolation on side surfaces, while terminal regions provide conductive connections. This local differentiation of properties allows the connection member to simultaneously achieve high current carrying capacity at terminals while maintaining compact size through insulated regions.
3Adaptability or versatility
If external busbars are installed outside the battery module, then connection flexibility is maintained, but susceptibility to short circuits from wear or deformation increases
Solution Approach 1:
The connection member is merged with the battery module structure, making it an integral part of the module rather than an external component. This integration protects the connection from external wear and deformation while maintaining electrical connection functionality.
Solution Approach 2:
Insulation members act as intermediary protective layers on the side surfaces of the connection member, preventing direct contact between the conductive connection member and surrounding components, thereby eliminating short circuit risks while allowing the connection member to maintain its structural integrity.
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 enhances the volume energy density of the battery pack by eliminating the need for external connections, reducing the risk of short circuits, and maintaining safety during deformation or wear, while maintaining efficient current transfer.
Implementation Method 1
insulation members disposed on side surfaces of the connection member main body in a stacking direction of the flat plate batteries
Implementation Method 2
The connection member has two terminals. A first terminal of the two terminals is connected to a terminal of the flat plate batteries. A second terminal of the two terminals is connected to a terminal of an adjacent battery module.
Data Source
AI summary
A battery module disposed in a battery pack includes a plurality of flat plate batteries that are stacked; a connection member having a connection member main body that has a plate-shape and disposed in parallel with the flat plate batteries in a stacking direction of the flat plate batteries; and insulation members disposed on side surfaces of the connection member main body in the stacking direction of the flat plate batteries. The connection member has two terminals, a first terminal of the two terminals is connected to a terminal of the flat plate batteries, and a second terminal is connected to a terminal of an adjacent battery module.