Battery Module Lead Assembly Without Busbars
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Solution Overview
Problem
Conventional battery modules require complex manufacturing processes and numerous parts for HV and LV connections, leading to reduced productivity and increased weight and cost.
Innovation Solution
A battery module design featuring a battery cell stack with first and second sensing blocks and an elastic member that covers the electrode leads, allowing for integrated HV and LV connections without the need for busbars, using flexible printed circuit boards or flat cables for sensing assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If busbars and busbar frames are used for HV connections, then reliable electrical connection is achieved, but device complexity and weight increase
Solution Approach 1:
The patent extracts and removes the busbar and busbar frame components from the battery module structure. Instead of using traditional busbars for HV connections, the invention uses the electrode leads directly, eliminating unnecessary components while maintaining reliable electrical connection functionality.
Solution Approach 2:
The electrode leads serve multiple functions: they provide both LV sensing connections and HV power connections. This multi-functionality eliminates the need for separate busbars, reducing device complexity while maintaining connection reliability through integrated design.
2Reliability
If multiple separate components (busbars, busbar frames, end plates) are used for connections, then connection reliability is improved, but manufacturing complexity and production time increase
Solution Approach 1:
The patent merges multiple separate components (busbars, busbar frames, end plates) into a simplified structure where the electrode leads directly establish both LV and HV connections. This consolidation reduces the number of parts and assembly steps, improving manufacturing efficiency while maintaining connection reliability through direct electrical contact.
3Measurement precision
If traditional sensing assemblies with separate connections are used, then measurement precision is maintained, but device complexity increases
Solution Approach 1:
The electrode leads serve dual purposes: providing HV power transmission and LV voltage sensing simultaneously. This multi-functional design maintains measurement precision by directly connecting sensing points to battery cells while eliminating separate sensing assembly components, thereby reducing device complexity.
Data Source
AI summary
A battery module including a battery cell stack in which a plurality of battery cells are stacked with a plurality of electrode leads protruding from the battery cell stack; a first sensing block and a second sensing block that cover the front surface and the rear surface of the battery cell stack with the plurality of protruding electrode leads, respectively; and an elastic member that covers both side surfaces of each of the first sensing block, the second sensing block, and the battery cell stack. At least two of the electrode leads are bent and joined after passing through a slit in the first sensing block or a slit in the second sensing block to form an electrode lead assembly, and the elastic member covers the electrode lead assembly.