Busbar Assembly With Buffer Structure for Battery Cell Expansion
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Solution Overview
Problem
Battery modules face damage due to expansion of battery cells and require insulation to prevent short-circuits, especially when using metal connections for busbars.
Innovation Solution
A busbar assembly with a buffer portion between connection points and a busbar holder made of insulating material, connected via thermal fusion, absorbs cell expansion and prevents short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery cells are connected using metal busbars and metal busbar holders, then electrical connection is achieved, but short-circuits may occur due to contact with external structures and additional insulation structures are required
Solution Approach 1:
The patent introduces an insulating busbar holder made of resin material as an intermediary component between the metal busbar and external structures. This mediator provides both mechanical support and electrical insulation, eliminating the need for additional insulation structures while preventing short-circuits with external components.
Solution Approach 2:
The busbar holder is constructed from composite material (resin) that combines mechanical strength with electrical insulation properties. This composite material replaces traditional separate metal holder plus insulation structure, achieving both structural support and electrical isolation in a single component.
2Reliability
If rigid busbar connections are used between battery cells, then stable electrical connection is achieved, but damage occurs when battery cells expand due to overcharge or aging
Solution Approach 1:
The busbar is designed with a buffer portion that can dynamically change its configuration in response to battery cell expansion. The buffer portion includes a deformation section that can bend or deform elastically, allowing the rigid busbar to adapt to changing cell dimensions while maintaining electrical connection.
Solution Approach 2:
The buffer portion of the busbar incorporates a flexible deformation section that can elastically deform to accommodate battery cell expansion. This flexible section acts as a shock-absorbing element that maintains electrical connectivity despite dimensional changes in the battery cells.
3Reliability
If additional insulation structures are added to prevent short-circuits, then electrical safety is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the functions of mechanical support and electrical insulation into a single busbar holder component. The resin holder simultaneously provides structural support for the busbar and electrical insulation to prevent short-circuits, eliminating the need for separate insulation structures and simplifying manufacturing.
Solution Approach 2:
The busbar holder is designed as a multi-functional component that performs both mechanical support and electrical insulation functions. This universal component replaces what would traditionally require multiple separate parts, reducing assembly steps and manufacturing complexity while maintaining electrical safety.
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
Reduces damage to battery modules and prevents short circuits by accommodating cell expansion and eliminating the need for additional insulation structures.
Implementation Method 1
a busbar holder made of insulating material, connected via thermal fusion
Data Source
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AI summary
The present disclosure provides a battery module comprising: a cell assembly including a plurality of battery cells; and a busbar assembly including a busbar electrically connected to at least one of the plurality of battery cells, and a busbar holder including a base located on the cell assembly and a protrusion part extending from the base and connected to the busbar. The plurality of battery cells may include a first battery cell and a second battery cell adjacent to the first battery cell. The busbar may include a first connection part connected to the first battery cell, a second connection part connected to the second battery cell, and a buffer part located between the first connection part and the second connection part. The protrusion part may be connected to the buffer part.