Reinforced Busbar Frame Structure to Prevent Battery Module Bending
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Solution Overview
Problem
The existing battery modules suffer from bending of the busbar frame due to insufficient rigidity when connecting electrode leads to busbars.
Innovation Solution
A battery module design that includes a busbar frame reinforced with metal reinforcing members, which are inserted into grooves and have wing portions to enhance rigidity, minimizing bending and ensuring stable electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the busbar frame is made lightweight and simple, then manufacturing cost and complexity are reduced, but the frame becomes prone to bending when electrode leads are connected
Solution Approach 1:
The busbar frame is constructed using composite material: a polymer base material provides lightweight and cost-effective properties, while embedded metal reinforcing members (steel plates) provide the necessary rigidity and strength. This composite structure resolves the contradiction by combining materials with complementary properties to achieve both simplicity and structural integrity.
Solution Approach 2:
Instead of making the entire busbar frame from heavy rigid material, metal reinforcing members are strategically positioned only in specific locations where strength is needed - namely at the busbar mounting portions and along the longitudinal edges. This local reinforcement approach maintains overall structural simplicity while providing targeted rigidity to prevent bending during electrode lead connection.
2Strength
If reinforcing members are added to the busbar frame, then bending is minimized and structural integrity is enhanced, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The metal reinforcing members are pre-positioned and embedded within the polymer material during the molding process. The grooves for the reinforcing members are pre-formed in the busbar frame structure, allowing for systematic integration rather than complex post-assembly operations. This preliminary preparation reduces manufacturing complexity despite adding reinforcement elements.
Solution Approach 2:
The busbar frame is segmented into functional zones: polymer portions for insulation and basic structure, metal reinforcing members for structural strength, and grooves for integration. This segmentation allows each component to be optimized independently and assembled through standardized processes, reducing overall device complexity while achieving the desired rigidity.
Data Source
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AI summary
A battery module according to an embodiment of the present disclosure includes a battery cell stack in which a plurality of battery cells is stacked, a module case for accommodating the battery cell stack, a busbar frame disposed on one side of the battery cell stack, one or more busbars disposed in the busbar frame, and one or more reinforcing members disposed in the busbar frame.