Fishbone Bus Bar Layout for Multi-Row Cylindrical Battery Modules
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Solution Overview
Problem
Existing battery modules face challenges in efficiently arranging and connecting a large number of cylindrical battery cells within a predetermined dimension, particularly when the number of cells in one bank exceeds certain limits, making it difficult to maintain effective electrical connections.
Innovation Solution
A battery module design featuring cylindrical battery cells arranged in multiple rows with a fishbone bus bar system that connects cells in series and parallel, utilizing a first terminal bus bar, a second terminal bus bar, and a fishbone bus bar to facilitate efficient electrical connections, along with a cell case and heat dissipation unit for thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a straight bus bar is used to connect cylindrical battery cells in one bank, then the connection is simple, but the bank length becomes too long when many cells are connected, exceeding the battery module dimension
Solution Approach 1:
The bus bar is segmented into a main body and multiple branch portions that extend in different directions. Instead of using a single long straight bus bar, the segmented design allows connections to multiple battery cells in different orientations, reducing the overall bank length while maintaining connection simplicity
Solution Approach 2:
The bus bar transitions from a one-dimensional straight line to a two-dimensional fishbone structure with branch portions extending perpendicular to the main body. This dimensional change allows the bus bar to connect battery cells arranged in multiple directions, effectively reducing the linear length requirement of the bank
2Ease of manufacture
If cylindrical battery cells are arranged in a single row, then the arrangement is simple, but a large number of cells cannot be arranged within the predetermined dimension of the battery module
Solution Approach 1:
The battery cells are arranged from a one-dimensional single row to a two-dimensional multi-row configuration. The fishbone bus bar structure enables this dimensional transition by providing connection points in multiple directions, allowing more cells to be packed within the same footprint while maintaining manufacturing simplicity
Data Source
AI summary
Disclosed is a battery module, which includes cylindrical battery cells erect such that top caps thereof face upward, and a bus bar unit connected to the cylindrical battery cells in series and in parallel. The cylindrical battery cells include a first bank cell group and a second bank cell group arranged in a first direction parallel to the first bank cell group. The bus bar unit includes a first terminal bus bar disposed on the first bank cell group and electrically connected to a positive electrode of each of the first cylindrical battery cells a second terminal bus bar disposed on the second bank cell group and electrically connected to a negative electrode of each of the second cylindrical battery cells, and a fishbone bus bar electrically connected to a negative electrode of the first cylindrical battery cells and a positive electrode of the second cylindrical battery cells.