Battery Module R-Bending Insulation for Short Prevention
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Solution Overview
Problem
Pouch-type battery cells connected in parallel are prone to electric shorts due to contact between electrode leads and the aluminum layer of adjacent pouch cases, and the bonding stability between electrode leads and bus bars is compromised, leading to potential ignition and complex assembly processes.
Innovation Solution
The battery module incorporates R bending portions on the pouch case to prevent electrode lead contact with the terrace front end and uses a bus bar assembly with movable and fixed bus bars and an adhering member to ensure mechanical compression and secure welding of electrode leads, eliminating the need for additional insulation and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pouch-type battery cells are connected in parallel with electrode leads overlapped and contacted on bus bar, then electrical connection is achieved, but electric short may occur between electrode lead and aluminum layer of pouch case
Solution Approach 1:
An insulating member is introduced as an intermediary between the electrode lead and the pouch case (specifically the aluminum layer). This insulating member prevents direct contact between conductive parts, eliminating the electric short risk while maintaining the parallel electrical connection structure.
Solution Approach 2:
The insulating member is positioned in advance to prevent the harmful contact between electrode lead and aluminum layer before it can occur. By pre-establishing this protective barrier, the design proactively prevents electric shorts rather than reacting to them.
2Object-affected harmful factors
If additional insulating sheet or insulation tape is applied between adjacent pouch-type battery cells, then electric short is prevented, but assembly process becomes complicated and cost increases
Solution Approach 1:
The insulating function is merged with the existing structural components of the battery module. Instead of adding separate insulating sheets or tapes as additional components, the insulating member is integrated into the parallel connection structure itself, combining insulation with the electrical connection framework.
Solution Approach 2:
The insulating member serves multiple functions: it provides electrical insulation to prevent shorts, maintains the structural arrangement of parallel connections, and facilitates the assembly process. This multi-functionality eliminates the need for separate insulation components and simplifies the overall assembly.
3Reliability
If multiple electrode leads are overlapped and welded to bus bar, then parallel electrical connection is achieved, but bonding stability is compromised
Solution Approach 1:
The insulating member acts as a mediator that organizes and separates the multiple electrode leads while they are being connected to the bus bar. This intermediary structure maintains proper alignment and spacing, ensuring stable bonding without the leads interfering with each other or the pouch case.
Data Source
AI summary
A battery module is provided. The battery module includes pouch-type battery cells stacked on each other and electrically connected in series and/or in parallel. Toward an electrode lead of one pouch-type battery cell, electrode leads of other pouch-type battery cells are biased to allow ends of the electrode leads to be overlapped. In particular, each of the pouch-type battery cells has an R bending portion at which a boundary region between a terrace of a pouch case and the electrode leads is bent toward a direction in which the electrode leads are biased.