Segmented Battery Module Housing and Busbar Assembly
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Solution Overview
Problem
Conventional battery modules with I-shaped frames face challenges in assembling cell stacks due to complexity, deformation, and damage during assembly, as well as limitations in increasing the height of the cell stack and improving cooling performance.
Innovation Solution
A battery module design featuring a housing with partitioned accommodation spaces, a busbar assembly with separate connections to each side of the partition, and a heat insulating member to prevent heat propagation, allowing for easier assembly and increased stack height while enhancing cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the opened end of the module housing is widened to insert the cell stack, then the cell stack can be accommodated, but the module housing may deform and the assembly process becomes complicated
Solution Approach 1:
The module housing is divided into an upper housing and a lower housing that can be separately assembled. The cell stack is inserted into the lower housing first, then the upper housing is coupled to complete the assembly. This segmentation eliminates the need to widen the opened end of a single housing, avoiding deformation while simplifying the assembly process.
2Adaptability or versatility
If multiple cell stacks are connected to a single busbar assembly, then the electrical connection is achieved, but tolerance accumulation makes welding difficult and defects increase
Solution Approach 1:
The busbar assembly is segmented into multiple separate busbar assemblies, with each cell stack connected to its own dedicated busbar assembly. This eliminates tolerance accumulation from connecting multiple cell stacks to a single busbar assembly, significantly improving welding precision and reducing defects.
3Ease of operation
If the number of battery cells in a cell stack is limited to improve assembly performance, then assembly is easier, but the height of the cell stack cannot be increased
Solution Approach 1:
The cell stack is segmented into multiple sub-stacks, each containing a manageable number of battery cells for easy assembly. Multiple sub-stacks are then vertically stacked to achieve the desired overall height. This segmentation allows both easy assembly of individual sub-stacks and increased total height through vertical stacking.
4Strength
If cell stacks are installed on both sides of a partition wall, then the I-shaped frame structure is formed, but the assembly process becomes more complicated
Solution Approach 1:
The module housing is segmented into upper and lower sections that are assembled separately. The cell stacks are installed in the lower housing first, then the upper housing is coupled to form the complete I-shaped frame structure. This segmentation maintains the structural strength of the I-shaped frame while simplifying the assembly process by avoiding the need to install cell stacks on both sides of a partition wall simultaneously.
Data Source
AI summary
A battery module includes a cell stack; a busbar assembly including at least one busbar electrically connected to the plurality of battery cells, and a busbar support member disposed between the at least one busbar and the cell stack; and a housing having a plurality of accommodation spaces partitioned by a partition member, wherein the cell stack includes a first stack disposed in a first accommodation space located on a first side of the partition member, and a second stack disposed in a second accommodation space located on a second side of the partition member; the busbar assembly includes a first assembly electrically connected to the first stack, and a second assembly electrically connected to the second stack; and the first assembly and the second assembly are electrically connected to at least one of both ends of the plurality of accommodation spaces.