Battery Module Busbar Frame Segmentation for Warpage Control
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Solution Overview
Problem
The warpage phenomenon during injection molding of busbar frames in battery modules becomes significant as the length of the busbar frame increases, leading to difficulties in mold control and assembly, which affects the quality and increases the defective rate of the battery module.
Innovation Solution
A battery module design featuring a busbar frame composed of a first and second busbar frame coupled along the stacking direction, with a protrusion part on one side of the first frame and a groove part on the second frame, allowing for slidable coupling to minimize warpage and enhance assembly, thereby reducing molding costs and improving module quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the length of the busbar frame is increased to accommodate more battery cells, then the battery module capacity is improved, but the warpage phenomenon during injection molding worsens
Solution Approach 1:
The busbar frame is divided into multiple segments (first busbar frame and second busbar frame) that are coupled together along the stacking direction of the battery cell stack. This segmentation allows each segment to be manufactured with controlled length, avoiding the warpage issues associated with long single-piece busbar frames, while still providing sufficient capacity to accommodate multiple battery cells through the combined structure.
2Device complexity
If the busbar frame is manufactured as a single long piece, then the structural simplicity is maintained, but the mold control difficulty increases
Solution Approach 1:
The busbar frame is divided into multiple segments (first busbar frame and second busbar frame) that are coupled together along the stacking direction of the battery cell stack. This segmentation allows each segment to be manufactured with controlled length, avoiding the warpage issues associated with long single-piece busbar frames, while still providing sufficient capacity to accommodate multiple battery cells through the combined structure.
3Area of stationary object
If the busbar frame length is increased, then the coverage area is improved, but the assembly difficulty increases
Solution Approach 1:
The busbar frame is divided into multiple segments (first busbar frame and second busbar frame) that are coupled together along the stacking direction of the battery cell stack. This segmentation allows each segment to be manufactured with controlled length, avoiding the warpage issues associated with long single-piece busbar frames, while still providing sufficient capacity to accommodate multiple battery cells through the combined structure.
Solution Approach 2:
Instead of extending the busbar frame length in one dimension, the patent extends the coverage area by stacking multiple busbar frame segments in the vertical direction (along the stacking direction of the battery cell stack). This dimensional approach allows coverage of larger areas while maintaining manageable segment lengths for easier assembly.
Data Source
AI summary
The present disclosure relates to a battery module for improving the quality of busbar frame, and a method for manufacturing the same. The battery module according to one embodiment of the present disclosure includes: a battery cell stack in which a plurality of battery cells are stacked, a module frame for housing the battery cell stack, and a busbar frame for covering the front and rear surfaces of the battery cell stack, wherein the busbar frame includes a first busbar frame and a second busbar frame coupled along a stacking direction of the battery cell stack, and wherein a protrusion part is formed on one side of the first busbar frame, a groove part is formed on one side of the second busbar frame, and the protrusion part is coupled to the groove part, so that the first busbar frame and the second busbar frame are connected.