Battery Module Busbar Holder Structure Against Welding Debris Shorts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The generation of foreign matter during the welding process in battery modules leads to instability and potential fire hazards due to short circuits between adjacent battery cells.
Innovation Solution
A battery module design incorporating a housing body with busbar holders, insulating parts, and penetration prevention parts that prevent foreign matter from entering gaps between battery cells, using features like first and second penetration prevention holders and covers to maintain separation and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If busbars are welded to battery cells to electrically connect them, then electrical connection is achieved, but foreign matter is generated that degrades battery stability
Solution Approach 1:
The patent introduces a busbar holder as an intermediary component between the busbar and battery cells. This holder receives the busbar through a penetration portion and provides a stable mounting structure, preventing welding debris from contaminating the battery cells while maintaining electrical connection stability.
Solution Approach 2:
The patent extracts the welding process from direct contact with battery cells by using a busbar holder as an intermediate receiving structure. The holder takes out the function of supporting the busbar away from the battery cell surface, thereby preventing foreign matter generated during welding from directly contaminating the battery cells.
2Quantity of substance
If battery cells are disposed closely to improve space utilization, then capacity density increases, but foreign matter can penetrate between cells causing short circuits
Solution Approach 1:
The patent uses an insulating part that extends between adjacent battery cells to form a protective barrier. This insulating structure acts as a flexible shield that prevents foreign matter from penetrating through the gaps between closely disposed battery cells, maintaining both high density and protection against contamination.
Solution Approach 2:
The insulating part serves as an intermediary barrier between adjacent battery cells. It fills the gap space between cells and prevents foreign matter generated during welding or handling from penetrating between cells, thereby preventing short circuits while allowing close packing for high capacity density.
3Reliability
If insulating parts are placed between battery cells to prevent short circuits, then electrical insulation is improved, but the structure becomes more complex
Solution Approach 1:
The patent merges the insulating part with the busbar holder structure, where the insulating part extends from the busbar holder between adjacent battery cells. This integration combines the support function of the busbar holder with the insulation function, reducing the number of separate components and simplifying the overall structure while maintaining effective electrical insulation.
Data Source
AI summary
A battery module includes a housing body, a plurality of battery cells disposed in the housing body and including terminal parts, a busbar connected to the terminal parts to electrically connect the plurality of battery cells, a busbar holder between the busbar and the plurality of battery cells, the busbar holder supporting the busbar, an insulating part between adjacent battery cells of the plurality of battery cells to insulate the adjacent battery cells from each other, and a penetration prevention part which prevents foreign matter from being introduced between the plurality of battery cells.