Busbar Frame Insulation Rib Layout for Compact Battery Modules
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Ensuring sufficient creepage distance between busbars in a limited space to improve insulation performance is a challenge in battery modules, particularly as capacity and output increase, with constraints on available space.
Innovation Solution
A battery module design featuring a busbar frame with integrated insulation ribs that protrude between busbars, increasing the creepage distance and enhancing insulation performance without significantly increasing space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the creepage distance between busbars is increased to improve insulation performance, then the insulation reliability is improved, but the space required increases
Solution Approach 1:
The insulation rib extends in the vertical direction (thickness direction of busbar frame) rather than only in the horizontal plane between busbars. This three-dimensional approach increases the creepage distance by utilizing the thickness dimension of the busbar frame, thereby improving insulation performance without increasing the planar space between adjacent busbars.
Solution Approach 2:
An insulation rib is introduced as an intermediary structure between adjacent busbars. This rib, made of insulating material, acts as a mediator that increases the creepage distance and improves insulation performance while occupying minimal space within the existing busbar frame structure.
2Quantity of substance
If the capacity and output of the battery module are increased, then the energy storage capability is improved, but the required creepage distance increases making space constraints more severe
Solution Approach 1:
The insulation rib utilizes the vertical thickness dimension of the busbar frame to increase creepage distance, allowing the battery module to accommodate higher capacity and output requirements without proportionally increasing the planar space between busbars.
3Productivity
If multiple busbars with different polarities are disposed adjacent to each other on a single busbar frame, then the electrical connection efficiency is improved, but the insulation design complexity increases
Solution Approach 1:
The insulation rib is selectively positioned between adjacent busbars of different polarities where insulation is required. This localized approach maintains efficient electrical connections between busbars of the same polarity while providing necessary insulation only where needed, simplifying the overall insulation design.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A battery module includes a battery cell stack including a plurality of battery cells, a busbar frame located on at least one surface of the battery cell stack, and at least two busbars located on the busbar frame. The busbar frame includes at least one insulation rib protruding between a first busbar of the at least two busbars and an adjacent second busbar of the at least two busbars. The insulation rib includes a plurality of protruding portions, the plurality of protruding portions be located on a first surface of the busbar frame, the first surface facing away from the first busbar, and the plurality of protruding portions protruding toward the second busbar.