Battery Module Assembly With Through-Module Busbars for Thermal Runaway
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Solution Overview
Problem
Conventional battery modules face issues with increased thickness, interference noise, exposure to flames during thermal runaway, and potential explosions due to the long electrical connection passages of busbars, which also act as heat diffusion paths.
Innovation Solution
The battery module design alternately stacks positive and negative electrodes at the ends of battery cells, with module busbars connected to lead tabs, and includes an inner plate for electrical connection between cells and pack busbars, minimizing the length of pack busbars and preventing short circuits by not positioning them above the battery module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional standardized battery modules are used with busbars disposed over the battery packs, then electrical connection between battery packs is achieved, but the thickness of the battery increases and the busbar is directly exposed to flame during thermal runaway
Solution Approach 1:
The patent repositions the busbar from a horizontal arrangement above the battery module to a vertical arrangement passing through the module. This dimensional change allows the busbar to connect battery packs without increasing the battery pack thickness, while also preventing direct exposure to flames during thermal runaway by routing it through the module structure rather than placing it on top.
2Reliability
If the busbar is disposed over the battery packs to connect battery packs, then electrical connection is established, but interference noise with the module is generated due to vibrations
Solution Approach 1:
The busbar is nested within the battery module structure, passing through the module rather than being disposed externally above it. This nesting approach protects the busbar from vibration-induced interference noise while maintaining electrical connection stability between battery packs.
3Reliability
If the busbar area is increased to connect battery packs, then electrical connection is achieved, but the busbar functions as a heat diffusion passage between modules
Solution Approach 1:
The battery module structure is segmented with the busbar passing through dedicated openings in the end plates and module housing. This segmentation isolates the busbar path, limiting its area and preventing it from functioning as a large heat diffusion passage between modules, thereby reducing thermal runaway propagation risk.
4Reliability
If conventional battery module design is used, then battery cells are connected in series to form modules, but the length of pack busbar is extended along a long way increasing weight and material cost
Solution Approach 1:
Instead of extending the busbar horizontally along the top of the battery pack to connect to adjacent packs, the patent inverts the approach by routing the busbar vertically through the module. This inversion shortens the busbar length significantly, reducing both weight and material cost while maintaining electrical connection capability between battery packs.
Data Source
AI summary
A battery module according to one embodiment of the present invention may include battery cells of which positive electrodes and negative electrodes which are formed at one end portions thereof are alternately stacked in a stacking direction, a pair of end plates coupled to both side ends of the stacked battery cells, and module busbars electrically connected to lead tabs provided on the battery cells, wherein, among the battery cells, battery cells disposed at both side ends of the battery module are disposed so that front ends and rear ends have the same electrode.