Busbar-Integrated Cell Frame for Stable Battery Module Connections

Solution Overview

Problem

Conventional methods for manufacturing battery packs are complicated and prone to busbar movement or separation due to poor adhesive application and hardening, leading to potential electrical connections being damaged.

Innovation Solution

A busbar-integrated cell frame is formed through insert injection molding, where the busbar and cell frame are integrally formed, eliminating the need for separate joining processes and preventing busbar movement or separation by filling through-holes with a resin component.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If adhesive is applied to fix the busbar to the cell frame, then the busbar can be attached to the frame, but the process becomes complicated and the busbar may still move or separate due to poor adhesive application or hardening

Engineering Contradiction:

Improvebonding strength between busbar and cell frameVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The busbar and cell frame are merged into a single integral structure through insert injection molding. The busbar is inserted into the mold cavity before injecting the thermoplastic resin that forms the cell frame, creating a permanently bonded joint without requiring separate adhesive application or hardening processes. This eliminates the complexity of multi-step adhesive processes while ensuring strong, reliable bonding.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The chemical bonding system (adhesive application and hardening) is replaced with a mechanical integration system (insert injection molding). The busbar is mechanically embedded into the cell frame structure during molding, creating a robust physical connection that eliminates the need for chemical adhesives and their associated process complexities.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If adhesive is used to fix the busbar, then the busbar can be attached to the frame, but the busbar may move or separate due to poor adhesive application

Engineering Contradiction:

Improvestability of busbar connectionVSAvoidease of busbar attachment

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The busbar and cell frame are merged into a single integral structure through insert injection molding. The busbar is inserted into the mold cavity before injecting the thermoplastic resin that forms the cell frame, creating a permanently bonded joint without requiring separate adhesive application or hardening processes. This eliminates the complexity of multi-step adhesive processes while ensuring strong, reliable bonding.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The chemical bonding system (adhesive application and hardening) is replaced with a mechanical integration system (insert injection molding). The busbar is mechanically embedded into the cell frame structure during molding, creating a robust physical connection that eliminates the need for chemical adhesives and their associated process complexities.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If the busbar is not fixed to the cell frame, then the manufacturing process is simpler, but the junction between battery cell and busbar may be damaged

Engineering Contradiction:

Improvesimplicity of manufacturing processVSAvoidprotection of electrical junction

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The busbar and cell frame are merged into a single integral structure through insert injection molding. The busbar is inserted into the mold cavity before injecting the thermoplastic resin that forms the cell frame, creating a permanently bonded joint without requiring separate adhesive application or hardening processes. This eliminates the complexity of multi-step adhesive processes while ensuring strong, reliable bonding.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The chemical bonding system (adhesive application and hardening) is replaced with a mechanical integration system (insert injection molding). The busbar is mechanically embedded into the cell frame structure during molding, creating a robust physical connection that eliminates the need for chemical adhesives and their associated process complexities.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 approach simplifies the manufacturing process, reduces the risk of busbar separation, and enhances the stability of electrical connections within the battery module, thereby improving the reliability and efficiency of the battery pack.

Implementation Method 1

the cell frame (200) and the busbar (300) are integrally formed by insert injection molding

Methodology Applied

Scientific EffectInjection molding:

Data Source

PatentUS20240213626A1Battery Module Including Busbar-Integrated Cell Frame

Publication Date: 2024.06.27 LG ENERGY SOLUTION LTD

AI summary

A battery module includes a plurality of battery cells, a cell frame configured to receive the plurality of battery cells, a busbar configured to connect the plurality of battery cells to each other in series and/or in parallel, and a bonding wire configured to electrically connect the battery cells to the busbar. The busbar includes one or more first busbars located at an upper part of the cell frame and two second busbars located at opposite side surfaces of the cell frame. The cell frame and the busbar are integrally formed by insert injection molding.