Busbar Through-Hole Battery Module for Compact Wiring Isolation
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Solution Overview
Problem
The complex wiring arrangement of external lead wires for positive and negative electrodes in battery connections increases the risk of contact and requires significant space, complicating the wiring and potentially reducing reliability.
Innovation Solution
A battery module design featuring a busbar with through-holes that electrically connects batteries, where the open rim of each battery is partially in contact with the busbar, and the sealing body is insulated from the busbar, allowing for simplified wiring and reduced space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external lead wires are extended from both top and bottom surfaces of the battery for positive and negative electrodes, then electrical connection is achieved, but space for wiring is significantly required and wiring becomes complicated
Solution Approach 1:
The patent merges the functions of the battery can and sealing body as electrical terminals by connecting them through a conductive structure. The battery can's bottom surface and the sealing body's outer surface are electrically connected via a conductive layer, allowing both positive and negative electrode connections to be made from the same side (top surface), thereby eliminating the need for separate top and bottom wiring and reducing wiring complexity.
2Area of stationary object
If external lead wires for positive and negative electrodes are arranged in proximity on the sealing body side, then space is saved, but the risk of contact between lead wires increases
Solution Approach 1:
The patent introduces an insulating structure as an intermediary between the conductive parts. The sealing body includes an insulating layer that prevents electrical contact between the battery can and external objects, while the conductive layer provides electrical connection. This intermediary arrangement allows lead wires to be arranged in proximity without risking contact, as the insulating structure maintains electrical isolation where needed.
3Reliability
If a wider space for wiring is provided to prevent lead wire contact, then insulation reliability is improved, but the space required for connecting batteries increases
Solution Approach 1:
The patent applies different electrical properties to different parts of the sealing body structure. The inner surface facing the battery can is made conductive for electrical connection, while the outer surface and side surfaces are made insulating for safety and proximity wiring capability. This local differentiation of electrical properties allows wiring to be compact without compromising insulation reliability, as insulation is provided only where lead wires are present.
Data Source
AI summary
A battery module including a plurality of batteries, and a busbar electrically connecting the batteries. The battery includes: a battery can including a cylindrical portion, a bottom wall closing one end of the cylindrical portion, and an open rim continuing to the other end of the cylindrical portion; an electrode body; and a sealing body which seals an opening defined by the open rim. The sealing body has a first principal surface facing an interior of the battery can, a second principal surface opposite to the first principal surface, and a side surface connecting the first principal surface with the second principal surface. The busbar has a plurality of through-holes fitted with the batteries. The open rim of each of the batteries fitted into the through-holes is at least partially in contact with the busbar. The sealing body and the busbar are electrically insulated from each other.