Secondary Battery Module With Embedded Bus Bars And Wing Terminals
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Solution Overview
Problem
Conventional secondary battery modules require a large number of components for electrical connection and mechanical restraints, leading to increased weight, volume, and manufacturing complexity when forming a battery pack.
Innovation Solution
A secondary battery module design featuring a rectangular shape with embedded bus bars and a terminal unit including wing terminals that reduce the number of bus bars needed for lead-out terminals, allowing for a reduced component count and integrated jig insertion without separate components, while utilizing a cooling fin and plate for structural support and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional battery module includes 12 cells or 24 cells, then the battery module can be assembled with standard configurations, but the number of battery modules required in the secondary battery pack increases, leading to increased weight and volume
Solution Approach 1:
The battery pack is divided into multiple battery modules, each containing a specific number of battery cells (12 or 24 cells). This segmentation allows for standardized manufacturing while enabling flexible configuration to achieve the desired total capacity, thereby optimizing the balance between ease of manufacture and weight reduction.
2Ease of manufacture
If a conventional battery module includes 12 cells or 24 cells, then the battery module can be assembled with standard configurations, but the number of components required for electrical connection and mechanical restraints increases
Solution Approach 1:
Multiple battery modules are arranged adjacent to each other and coupled together, merging their structural and electrical functions. This consolidation reduces the total number of separate components required for electrical connection and mechanical restraints, as adjacent modules can share common structural elements and connection points.
3Quantity of substance
If multiple battery modules are mounted to increase energy, then the energy capacity increases, but the volume density decreases due to increased number of components
Solution Approach 1:
Battery modules are arranged in a compact configuration where adjacent modules share common structural elements and cooling plates. This nested-like arrangement allows multiple modules to occupy less total volume by eliminating redundant components at the interfaces between modules, thereby maintaining high volume density while increasing energy capacity.
4Quantity of substance
If multiple battery modules are mounted to increase energy, then the energy capacity increases, but the number of manufacturing processes increases
Solution Approach 1:
The cooling plate and structural components are designed to serve multiple adjacent battery modules simultaneously. Each cooling plate can cool multiple modules, and structural elements can provide mechanical support for multiple modules, thereby reducing the total number of manufacturing processes required compared to treating each module as a completely separate unit.
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 reduces the number of components and assembly costs, decreases the volume and weight of the battery pack, and enables a high-output battery pack with improved energy density by packing more cells in a compact form.
Implementation Method 1
a cooling plate which is coupled to a plurality of sub modules arranged adjacent to each other
Implementation Method 2
side structures having a bus bar embedded therein... electrically connect with each other
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(b)
Figure 3
AI summary
The secondary battery module includes: A secondary battery module, comprising: a plurality of sub modules, each including battery cell and cooling fin wherein the battery is disposed on both side surfaces of the cooling fin; a cooling plate which is coupled to the plurality of the sub modules; and side structures having bus bars, wherein a terminal unit is disposed at each of the plurality of sub modules, wherein the terminal unit includes a contact terminal disposed between electrode tabs of the battery cells; and a wing terminal which extends outwavdly from one end of the contact terminal, wherein the terminal unit disposed at one of the plurality of sub modules is connected with another terminal unit disposed at another sub module by one of the bus bars.