Busbar Support Guide Structure for Battery Cell Insulation
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Solution Overview
Problem
During the assembly of battery modules, direct contact between the case of a battery cell and adjacent conductive materials can lead to current leakage, causing dielectric breakdown and potential safety hazards such as fire.
Innovation Solution
A battery module design incorporating a support frame with a support guide that spaces apart the sealing portions of adjacent battery cells, using a protrusion to guide these portions away from each other, and a busbar assembly with a frame body and support portions to prevent interference and ensure proper electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If battery cells are assembled with sealing portions in direct contact, then assembly simplicity is improved, but dielectric breakdown occurs due to current leakage through conductive materials
Solution Approach 1:
A support guide structure is introduced as an intermediary component between adjacent battery cells. The support guide includes a guide groove that receives and spaces the sealing portions, preventing direct contact between conductive parts of adjacent cells. This mediator maintains electrical insulation while enabling assembly, resolving the contradiction between assembly simplicity and insulating performance.
2Reliability
If support guide structures are added to space sealing portions, then insulating performance is improved, but device complexity increases
Solution Approach 1:
The support guide is integrated with the support frame as a unified structure, combining multiple functions into a single component. The support guide includes both support functionality and the guide groove for spacing sealing portions, merging structural support and electrical insulation functions. This integration reduces the number of separate components, thereby limiting the increase in device complexity while maintaining improved insulating performance.
3Reliability
If protrusions are designed to increase distance toward the lower cover, then dielectric breakdown prevention is improved, but manufacturing precision requirements increase
Solution Approach 1:
The support guide groove is pre-formed in the support frame before battery cell assembly. The groove's geometry and position are predetermined during frame manufacturing, establishing the spacing relationship between sealing portions in advance. This preliminary action ensures consistent spacing without requiring high-precision positioning during the assembly process, thereby reducing manufacturing precision requirements while maintaining dielectric breakdown prevention.
Data Source
Figure 9
AI summary
A battery module includes a plurality of battery cells, each including a case and a sealing portion provided on at least one edge of the case, and including a first battery cell and a second battery cell adjacent to each other in a first direction; and a support frame opposite the plurality of battery cells and into which at least a portion of the sealing portion is inserted, wherein the support frame includes a support guide configured to guide at least portions of the sealing portion of the first battery cell and the sealing portion of the second battery cell to be spaced apart from each other in opposite directions with respect to the first direction.