Pouch Battery Module Bus Bar Layout for Higher Energy Density
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery modules, particularly those with pouch-type cells, suffer from low space utilization and energy density due to unused space between bus bar assemblies and electrode leads, leading to capacity loss and increased resistance, which is exacerbated by the need for reduced height and increased width for rapid charging.
Innovation Solution
A battery module design featuring pouch-type cells with an electrode accommodation portion having a wider width than height, coupled with a bus bar assembly where electrode leads extend vertically and are sealed by multiple bending portions, reducing the exposed area and allowing for efficient stacking and connection, along with a module housing for improved cooling and space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bus bar assemblies are disposed to electrically connect to battery cells, then electrical connection is achieved, but dead space is formed between bus bar assemblies and PCB reducing space utilization
Solution Approach 1:
The bus bar assembly is integrated with the PCB by disposing the PCB on the rear surface of the bus bar assembly, merging two separate components into a combined structure that eliminates dead space while maintaining both electrical connection and control functions
Solution Approach 2:
The PCB is disposed on the rear surface (vertical dimension) of the bus bar assembly rather than in the horizontal plane, utilizing the vertical space above the battery cells to eliminate horizontal dead space between components
2Speed
If battery cell width is increased to reduce resistance for rapid charging, then charging speed is improved, but dead space between bus bar assemblies increases reducing energy density
Solution Approach 1:
The bus bar assembly and PCB are merged into a single integrated structure, eliminating the horizontal gap that would otherwise increase with larger battery cell widths, thus maintaining high energy density while allowing larger cell dimensions for rapid charging
3Volume of moving object
If module height is reduced to improve space utilization, then packaging efficiency is improved, but cooling performance may be degraded
Solution Approach 1:
The cooling channels are configured to extend in the vertical direction through the bus bar assembly, utilizing the vertical dimension for heat dissipation while maintaining a compact horizontal footprint, thus achieving both reduced module height and effective cooling performance
Data Source
AI summary
A battery module includes a plurality of pouch-type battery cells, each of the pouch-type battery cells including an electrode assembly, a pouch, and electrode leads, the pouch including at least one electrode accommodation portion and a sealing portion; and a bus bar assembly having at least one conductive bus bar, wherein the electrode accommodation portion includes a body portion having a width greater than a height thereof, and an extension portion extending in a height direction and protruding from a central portion of the body portion, wherein the electrode leads are extending in the height direction, wherein the bus bar is coupled to the electrode leads in a vertical direction of the pouch-type battery cell, and wherein the upper end of the bus bar in the height direction is lower than an upper end of an extension portion of the pouch.