Assembled Battery Single-Surface Bus Bar Connection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing assembled batteries face challenges in productivity and complexity due to their structure, requiring a simpler and more efficient method for connecting unit cells while maintaining a high degree of freedom in connection modes.
Innovation Solution
The proposed solution involves a battery configuration with unit cells having flat main bodies and tabs, where positive and negative electrode bus bars are connected on a single surface, allowing for series-parallel connections with a reduced number of components and simplified assembly, using a combination of bus bars and conductive members for efficient electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional bus bar connection methods are used with series welding parts and parallel welding parts, then reliable electrical connections are achieved, but the structure becomes complex and assembly difficulty increases
Solution Approach 1:
The patent combines series connection and parallel connection functions into a single bus bar structure. The bus bar simultaneously serves as both a series connector (connecting positive to negative terminals across cells) and a parallel connector (connecting multiple positive tabs or negative tabs together), eliminating the need for separate series welding parts and parallel welding parts. This merging reduces structural complexity while maintaining connection reliability.
Solution Approach 2:
The bus bar is designed to perform multiple functions: it provides series connection between cell units, parallel connection between multiple tabs, and mechanical support structure. This multi-functional design reduces the total number of components needed and simplifies the overall assembly structure while ensuring reliable electrical connections.
2Reliability
If multiple separate components are used for series and parallel connections, then connection reliability is maintained, but the number of components increases and productivity decreases
Solution Approach 1:
By merging series connection and parallel connection into a single bus bar component, the number of parts to be handled during assembly is reduced. This eliminates multiple separate welding operations and reduces assembly steps, thereby improving productivity while maintaining connection reliability through the integrated design.
Solution Approach 2:
The bus bar is pre-configured with the necessary connection geometries and welding positions before assembly. The series and parallel connection paths are built into the bus bar structure in advance, allowing for faster assembly operations without compromising connection quality or reliability.
3Productivity
If a simple bus bar structure is used, then assembly is easier and productivity improves, but the degree of freedom in connection modes is limited
Solution Approach 1:
The bus bar is designed with universal connection capabilities that can accommodate different connection configurations. By adjusting the connection positions and configurations of the unit cells, various series-parallel connection modes can be achieved using the same bus bar structure, providing high adaptability without increasing complexity.
Solution Approach 2:
The bus bar structure incorporates segmented connection points that can be independently configured for series or parallel connections. This segmentation allows flexible arrangement of connection modes while maintaining a relatively simple overall structure, enabling adaptability to different battery pack configurations.
4Reliability
If traditional multi-component connection structures are used, then electrical connections are reliable, but the assembled battery size increases
Solution Approach 1:
By merging multiple connection functions into a single bus bar component, the overall volume required for connection structures is reduced. The integrated design eliminates the need for separate series and parallel welding parts, reducing the space occupied by connection components and allowing for more compact battery assembly.
Data Source
AI summary
An assembled battery includes a cell stack formed by stacking a plurality of unit cells in the same direction, positive electrode-side bus bars respectively connected to positive electrode tabs of the unit cells, and negative electrode-side bus bars respectively connected to negative electrode tabs of the unit cells. A positive electrode-side bus bar connected to a positive electrode tab of a first unit cell of adjacent unit cells in the cell stack, and a negative electrode-side bus bar connected to a negative electrode tab of a second unit cell, are connected to each other on one of the surfaces of the cell stack.