Aligned Busbar Structure for Standardized Cylindrical Cell Welding
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Solution Overview
Problem
The lack of standardization in busbar designs for cylindrical batteries leads to inefficiencies in production, requiring separate verification of process parameters and increased manufacturing costs due to the need for various molds and inspection tools.
Innovation Solution
A busbar design with integrated first and second connecting portions, aligned with the central axes of battery cells, facilitating series or parallel connections, and made of aluminum alloy to enhance reliability and conductivity, while standardizing the production process and reducing tooling costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different types of busbars are designed for cylindrical batteries, then the adaptability to different battery configurations is improved, but the device complexity increases due to the need for multiple molds and inspection tools
Solution Approach 1:
The busbar is designed with a universal structure that can accommodate different battery configurations through standardized connecting portions. The first and second connecting portions are designed with consistent geometries that can weld to both positive and negative electrodes, allowing the same busbar design to serve multiple connection configurations without requiring different molds or inspection tools.
Solution Approach 2:
The busbar is divided into distinct first and second connecting portions with a connecting section in between. Each connecting portion is designed with standardized features that can independently weld to different electrode types, while the connecting section provides a standardized transition. This segmentation allows modular adaptation to different configurations without increasing overall device complexity.
2Reliability
If separate verification of process parameters is performed for different busbar designs, then the reliability of product assembly is improved, but the loss of time increases due to repeated verification processes
Solution Approach 1:
By designing the busbar with universal connecting portions that have consistent geometries and welding features, the same process parameters can be used across different busbar applications. This eliminates the need for separate verification of process parameters for each busbar type, reducing verification time while maintaining assembly reliability through standardized connection mechanisms.
3Productivity
If standardized busbar design is implemented, then the productivity increases by reducing verification time and tooling variety, but the adaptability to specialized configurations may be reduced
Solution Approach 1:
The standardized busbar design achieves universality by creating connecting portions that can accommodate multiple configurations through consistent welding interfaces. The first and second connecting portions are designed with geometries that can weld to both positive and negative electrodes, providing sufficient adaptability for standard battery configurations while enabling high-speed production through standardized processes and reduced tooling variety.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design improves production efficiency, reduces costs, and enhances the reliability of battery connections by standardizing the busbar structure, allowing for precise welding and reduced tooling needs, thus enabling cost-effective mass production of battery modules and packs.
Implementation Method 1
The first connecting portion is welded to a positive electrode or a negative electrode of a first battery cell. The second connecting portion is connected to the first connecting portion and welded to a negative electrode or a positive electrode of a second battery cell
Data Source
AI summary
A busbar includes a first connecting portion and a second connecting portion connected the first connecting portion. The first connecting portion is welded to a positive electrode or a negative electrode of a first battery cell. The second connecting portion is welded to a negative electrode or a positive electrode of a second battery cell. A central axis of the first connecting portion, a central axis of the second connecting portion, and a central axis of the first battery cell and the second battery cell are coincided with each other.