Battery Module Busbar Frame Thermal Deformation Prevention
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Solution Overview
Problem
Existing busbar frames in battery modules deform thermally due to reduced thickness, which hinders the reduction of material costs and energy density improvements.
Innovation Solution
A busbar design incorporating a heat-resistant member between the busbar body and frame, using a polymer with a high glass transition temperature to prevent heat transfer and thermal deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the thickness of the busbar is reduced to lower material costs and increase energy density, then material cost and energy density are improved, but heat transfer to the busbar frame increases causing thermal deformation
Solution Approach 1:
A heat-resistant member is introduced as an intermediary component between the busbar and the busbar frame. This heat-resistant member acts as a thermal barrier that prevents heat generated by the thin busbar during charging and discharging from transferring to the busbar frame, thereby preventing thermal deformation of the frame while allowing the busbar to maintain reduced thickness for cost and energy density benefits.
2Ease of manufacture
If the thickness of the busbar is reduced, then manufacturing cost decreases and energy density increases, but the busbar frame undergoes thermal deformation
Solution Approach 1:
The heat-resistant member serves as a protective intermediary that isolates the busbar frame from thermal effects. This allows the busbar to be manufactured with reduced thickness at lower cost while the heat-resistant member prevents the frame from experiencing thermal deformation that would compromise manufacturing precision and dimensional stability.
3Quantity of substance
If the thickness of the busbar is reduced, then energy density of the battery module increases, but heat transfer to the busbar frame causes deformation
Solution Approach 1:
The heat-resistant member functions as a thermal intermediary that enables the busbar to be thinner for higher energy density while preventing the frame from undergoing shape changes due to heat transfer. The heat-resistant member absorbs or blocks the thermal energy, maintaining the frame's shape stability despite the reduced busbar thickness.
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 material costs and increases energy density while preventing busbar frame deformation, maintaining electrical connectivity.
Implementation Method 1
a heat-resistant member interposed between the busbar and the busbar frame
Implementation Method 2
using a polymer with a high glass transition temperature to prevent heat transfer and thermal deformation
Data Source
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AI summary
A battery module according to one embodiment of the present disclosure comprises a battery cell stack in which a plurality of battery cells are stacked, a busbar frame formed on one surface or both surfaces of the battery cell stack, and a busbar electrically connected to the electrode lead of the battery cell stack on the outer surface of the busbar frame, wherein the busbar includes a busbar body connected to the electrode lead and a heat-resistant member interposed between the busbar and the busbar frame.