Dual-Tab Battery Module Layout for Lower Resistance and Heat Imbalance
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Solution Overview
Problem
Long-width or ultra-long-width battery cells face increased internal resistance, power loss, and reduced lifespan due to spatial constraints and temperature imbalances, which also lead to potential bending issues.
Innovation Solution
A battery module design featuring a plurality of battery cells with electrode tabs at both ends, connected via first and second bus bar assemblies, and a sensing unit connected to one bus bar to monitor cell states, improving space efficiency and reducing internal resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If long-width or ultra-long-width battery cells are used to meet spatial constraints and improve energy density, then the width of the battery cell is increased, but the internal resistance and power loss increase
Solution Approach 1:
The battery cell is divided into multiple battery packs arranged in parallel, with electrode tabs positioned at both ends. This segmentation reduces the current path length within each pack, lowering internal resistance and power loss while maintaining the overall width for high energy density.
2Quantity of substance
If long-width or ultra-long-width battery cells are used to meet spatial constraints, then the width of the battery cell is increased, but the temperature difference between regions increases
Solution Approach 1:
Dividing the battery into multiple packs with tabs at both ends distributes heat generation more uniformly across the cell width, reducing regional temperature differences and improving thermal management effectiveness.
Solution Approach 2:
The bus bar configuration is optimized locally at both ends of the battery cell, providing enhanced current collection and heat dissipation pathways at critical regions, thereby balancing temperature distribution across the entire cell.
3Quantity of substance
If long-width or ultra-long-width battery cells are used, then the width of the battery cell is increased, but the cell may bend due to its own weight
Solution Approach 1:
Segmenting the battery into multiple smaller packs reduces the overall flexibility and weight concentration, making the cell more rigid and resistant to bending under its own weight while maintaining the required width for high energy density.
4Reliability
If sensing units are installed to monitor battery cell performance, then performance monitoring is improved, but the device complexity and space requirements increase
Solution Approach 1:
The sensing unit is integrated with the existing bus bar structure, combining monitoring functions with the current collection system. This reduces device complexity and space requirements while maintaining comprehensive performance monitoring capability.
Solution Approach 2:
The bus bar assembly serves dual purposes: current collection and structural support for the sensing unit. This multi-functionality reduces the need for separate sensing structures, simplifying the overall design and reducing space requirements.
Data Source
AI summary
A battery module includes: a plurality of battery cells which have positive electrode tabs and negative electrode tab formed at both ends thereof, respectively, wherein the plurality of battery cells are stacked; a first bus bar assembly having first bus bars to which the positive electrode tabs and the negative electrode tabs located at one end of the battery cells are connected; a second bus bar assembly having second bus bars to which the positive electrode tabs and the negative electrode tabs located at the other end of the battery cells are connected; and a sensing unit which is connected to any one bus bar of the first and second bus bars to detect states of the battery cells.