Battery Module Layout With Facing Busbar Frames and Cross-Beam Cooling
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Solution Overview
Problem
Conventional battery modules with expandable structures face complications due to the need for separate insulating covers and end plates, leading to increased weight, complex assembly processes, and intricate cooling systems, especially in multi-cell block configurations.
Innovation Solution
A battery module design featuring a busbar frame on cell block surfaces, a module frame housing the blocks, and an upper plate covering all surfaces, eliminating the need for separate end plates and insulating covers, with integrated thermal conductive resin layers and a refrigerant flow path through a cross beam for simplified cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate insulating covers and end plates are provided for each battery cell stack in an expandable battery module, then electrical insulation and physical protection are ensured, but the weight of the battery module increases and the structure becomes complicated
Solution Approach 1:
The end plate and insulating cover are merged into a single integrated end plate structure. The insulating cover is formed as an integral part of the end plate, eliminating the need for separate components. This integration maintains both electrical insulation and physical protection functions while simplifying the overall module structure and reducing the number of parts.
Solution Approach 2:
The integrated end plate serves multiple functions simultaneously: it provides physical protection for the battery cell stack, ensures electrical insulation through the integrated insulating cover, and maintains structural integrity. This multi-functional design reduces component count and simplifies assembly while preserving all necessary protective functions.
2Reliability
If separate insulating covers and end plates are provided for each battery cell stack, then electrical insulation and physical protection are ensured, but the production process is lengthened
Solution Approach 1:
The end plate and insulating cover are manufactured as a single integrated component, reducing the number of assembly steps required during production. This integration eliminates the need to separately install the insulating cover and end plate, thereby shortening the production process and improving manufacturing efficiency while maintaining protective functions.
Solution Approach 2:
The insulating cover is pre-integrated into the end plate structure during manufacturing, so that no additional assembly steps are required during battery module production. This preliminary integration of components streamlines the production process and reduces assembly time.
3Reliability
If conventional end plate and insulating cover structure is applied to expandable battery module with multiple cell blocks, then each cell stack is protected, but the cooling system arrangement becomes complicated
Solution Approach 1:
The integrated end plate structure provides a unified mounting surface and simplified geometry that facilitates easier arrangement of cooling systems. By eliminating the separate insulating cover, the cooling system can be more directly integrated with the end plate structure, reducing complexity in multi-cell block configurations.
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
The design reduces weight, simplifies assembly, lowers production costs, and enhances cooling efficiency by integrating components, resulting in a more compact and efficient battery module structure.
Implementation Method 1
integrated thermal conductive resin layers
Implementation Method 2
refrigerant flow path through a cross beam for simplified cooling
Data Source
AI summary
A battery module includes a cell block assembly having a battery cell stack in which a plurality of battery cells are stacked and a busbar frame mounted on at least one of the front and rear surfaces of the battery cell stack, a module frame that houses the cell block assembly and is opened in the front and rear surfaces, an upper plate that covers the upper surface and front and rear surfaces of the cell block assembly, and a cross beam that is disposed adjacent to a side surface part of an upper plate covering the front and rear surfaces of the cell block assembly, and is formed in a straight line shape. The cell block assembly includes a first cell block assembly and a second cell block assembly arranged side by side in a longitudinal direction of the battery cell. The first cell block assembly and the second cell block assembly are arranged separately from each other so that the busbar frames mounted on the first and second cell block assemblies face each other.