Battery Pack Frame and Busbar Layout for Insulation Sheet Fixation
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Solution Overview
Problem
Conventional battery modules face challenges in stable fixation of insulation sheets during abnormal explosions and have complex installation structures, leading to inefficiencies and increased manufacturing costs.
Innovation Solution
A battery pack design that eliminates the need for a holder for electrical connection of battery cells, featuring a streamlined configuration with frame portions and busbars that securely connect battery cells without deformation due to welding heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulation sheet is fixed to the vent portion of the battery cell by an adhesive member, then the insulation sheet can be installed, but stable fixation is not achieved in the event of an abnormal explosion of the battery cell
Solution Approach 1:
The frame portion is divided into multiple components: a main frame body, a separate insulation sheet insertion portion, and a holder component. This segmentation allows the insulation sheet to be securely positioned within a dedicated structural compartment rather than relying on adhesive fixation alone, improving reliability while maintaining structural organization.
Solution Approach 2:
The insulation sheet is placed within a dedicated insertion portion of the frame structure that acts as an intermediary between the battery cell vent portion and the external environment. This structural intermediary provides stable positioning and fixation of the insulation sheet without requiring adhesive members, solving both the reliability and complexity issues.
2Ease of manufacture
If the insulation sheet is installed on the holder busbar, then the insulation sheet can be positioned, but the installation structure is complicated, resulting in an inefficient structure
Solution Approach 1:
The insulation sheet insertion portion is merged into the frame portion structure itself, combining the functions of structural support and insulation sheet positioning into a single integrated component. This eliminates the need for separate holder busbars and complex installation structures, improving manufacturing efficiency while reducing overall structural complexity.
Solution Approach 2:
The frame portion serves multiple functions: it provides structural support for the battery cell, contains the insulation sheet within its insertion portion, and eliminates the need for separate holder components. This multi-functionality simplifies the overall installation structure and improves manufacturing efficiency by reducing the number of parts and assembly steps.
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 achieves stable and efficient electrical connections between battery cells, reduces manufacturing costs, and enhances durability by preventing deformation from welding heat, while also simplifying the installation process.
Implementation Method 1
an insulation sheet (mica sheet) is installed to prevent heat propagation when malfunction of a battery cell occurs
Implementation Method 2
The insulation sheet is fixed to the vent portion of the battery cell of the battery pack by an adhesive member
Data Source
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AI summary
A battery pack may include two or more battery cells arranged in a first direction each having a terminal portion including a first terminal and a second terminal. A side frame accommodates the battery cells. Two or more frame portions are on and coupled to an upper portion of the battery cells and an upper portion of the side frame. Each of the frame portions include an insertion portion extending in a width direction. Two or more busbars are coupled to the frame portions and electrically connect the battery cells to each other. An insulation sheet is accommodated in the insertion portion in each of the frame portions.