Zigzag Battery Module Terminals for Busbar-Free Pack Assembly
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Solution Overview
Problem
Existing battery module connections require separate busbars for electrical connection, limiting space efficiency and assembly flexibility, and necessitate specific directional assembly.
Innovation Solution
A battery module design with symmetrical connection terminals at opposite sides, allowing for easy assembly in any direction and eliminating the need for separate busbars, utilizing a concave-convex coupling mechanism for efficient electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If connection terminals are arranged at centers of opposite sides in zigzag manner, then assembly flexibility and space efficiency are improved, but manufacturing complexity increases
Solution Approach 1:
The connection terminals are arranged in a zigzag pattern at the centers of opposite sides rather than in a straight line, creating an asymmetric configuration that enables flexible assembly orientations while maintaining manufacturing feasibility through standardized terminal designs
Solution Approach 2:
The connection terminals serve dual functions: they provide electrical connection and enable mechanical coupling between battery modules. The symmetric arrangement with positive and negative terminals at opposite sides allows the same terminal design to work for both connection purposes regardless of assembly direction
2Reliability
If separate busbars are used for electrical connection, then electrical connection reliability is improved, but space efficiency deteriorates
Solution Approach 1:
The electrical connection function previously performed by separate busbars is merged into the connection terminals themselves. The terminals are designed to provide both mechanical coupling and electrical connection through integrated positive and negative terminal structures, eliminating the need for additional busbar components
Solution Approach 2:
The connection terminals are designed to perform multiple functions simultaneously: mechanical coupling between modules and electrical connection through the integrated positive and negative terminals. This multi-functional design replaces the need for separate busbars while maintaining connection reliability
3Manufacturing precision
If connection terminals are arranged asymmetrically, then assembly direction is constrained, but manufacturing precision is improved
Solution Approach 1:
While the overall arrangement is asymmetric (zigzag pattern), the terminal pairs themselves are symmetrically positioned at the centers of opposite sides. This allows standardized manufacturing processes while enabling flexible assembly in multiple directions through the alternating positive-negative terminal configuration
Data Source
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AI summary
The present invention relates to a battery module capable of improving coupling space efficiency and more particularly to a battery module including one or more battery cells received in a case and a connection terminal including at least one pair of a positive electrode terminal and a negative electrode terminal disposed at a middle part of each of opposite side surfaces of the case, wherein the positive electrode terminal and the negative electrode terminal are connected to the battery cells in the case, each of the positive electrode terminal and the negative electrode terminal protrudes outwards, and the positive electrode terminal, a gap between the positive electrode terminal and the negative electrode terminal, and the negative electrode terminal are disposed at equal intervals based on the center of the case.