Three-Dimensional Battery Bus Bar Design for Misalignment Absorption
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Solution Overview
Problem
Conventional power supply devices using secondary batteries face challenges in maintaining consistent electrical connections between battery cells due to manufacturing tolerances and external forces, which require a flexible bus bar that can absorb misalignment and stress, but existing flexible bus bars with bent portions between terminal connections are difficult to form when terminal sizes are short.
Innovation Solution
A bus bar with a three-dimensional coupling structure featuring first and second rising portions connected via bent portions, allowing for reduced distance between connection points and enhanced flexibility to absorb displacements in three directions, while maintaining strength through specific thicknesses at bent portions, and utilizing different metal materials for connection portions to facilitate deformation and welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If bending processing is carried out to provide flexibility in the bus bar, then the bus bar can absorb misalignment and stress, but the bent portion disposed between two connection parts makes forming difficult when terminal size is short
Solution Approach 1:
The bus bar transitions from a conventional planar configuration to a three-dimensional structure with multiple rising portions and bent portions extending in different spatial directions. This dimensional change allows the connection parts to be positioned closer together while maintaining the necessary flexibility and stress absorption capabilities through vertical and diagonal extensions rather than horizontal bending only.
Solution Approach 2:
The bus bar is divided into multiple distinct portions including first connection part, first rising portion, first bent portion, second rising portion, second bent portion, and connection part. This segmentation allows each portion to serve specific functions (connection, flexibility, stress absorption) independently, enabling the connection parts to be positioned closer while maintaining overall performance.
2Adaptability or versatility
If the bus bar is made thinner to improve flexibility, then deformation becomes easier, but the overall strength of the bus bar decreases
Solution Approach 1:
The bus bar employs different thickness specifications for different portions: the connection parts have sufficient thickness for strength and welding, while the bent portions have reduced thickness (0.8-2.0 mm) for flexibility. This local differentiation allows the bus bar to be both strong where needed and flexible where required, resolving the contradiction between overall strength and localized flexibility.
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
The solution enables downsizing of the bus bar with high flexibility to absorb displacements in X, Y, and Z axes, ensuring reliable electrical connections and effective displacement absorption, while allowing for easier manufacturing and welding processes.
Implementation Method 1
the bus bar has flexibility capable of being resiliently deformed
Implementation Method 2
bus bars 7 which electrically connects the electrode terminals 13 facing each other in battery cells 1 adjacently disposed
Data Source
AI summary
A power supply device includes: a bus bar which connects the electrode terminals facing each other. The bus bar includes: a first connection portion which is connected to one of the electrode terminals; a second connection portion which is connected to another of the electrode terminals; a first rising portion which is coupled to the first connection portion through a first bent portion; a second rising portion which is coupled to the second connection portion through a second bent portion, and is disposed in an orientation of crossing the first rising portion; and a middle linking portion which is coupled to the first rising portion through a third bent portion facing the first bent portion, and the second rising portion through a fourth bent portion facing the second bent portion.