Battery Busbar Bridge Portions Vibration Absorption
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Solution Overview
Problem
The increasing demand for rechargeable lithium batteries in various applications poses challenges in ensuring reliable electrical connections and efficient soldering processes, particularly due to vibrations and the need for multiple soldering attempts, which affects the quality and longevity of battery busbar connections.
Innovation Solution
A battery busbar design featuring a conductive sheet with bridge portions acting as vibration buffers and terminal contact portions, where the bridge portions are connected to the conductive sheet and terminal contact portions, increasing the electric current path and resistance, thereby ensuring stable connections and improving soldering quality by directing current flow through soldering points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bridge portions are added to connect terminal contact portions to the conductive sheet, then vibration absorption and connection reliability are improved, but device complexity increases
Solution Approach 1:
The busbar is divided into distinct functional segments: terminal contact portions for electrical connection, bridge portions for mechanical coupling and vibration absorption, and a conductive sheet for current distribution. This segmentation allows each part to optimize its specific function while working together as a unified structure.
Solution Approach 2:
The bridge portions are designed with flexible characteristics that allow them to dynamically absorb vibrations and accommodate thermal expansion/contraction. The structure transitions from a rigid fixed connection to a dynamic vibration-absorbing connection, improving reliability under varying operating conditions.
2Manufacturing precision
If bridge portions are designed with increased current path length, then soldering quality is improved through better current distribution, but electrical resistance increases
Solution Approach 1:
Different regions of the busbar have different properties: terminal contact portions have large cross-sections for low contact resistance, bridge portions have optimized geometry for vibration absorption, and the conductive sheet provides distributed current paths. The local geometry of bridge portions is specifically designed to balance current distribution needs with mechanical vibration absorption.
Solution Approach 2:
The current path is extended not just in length but also in spatial distribution across multiple dimensions. The conductive sheet with its extended surface area provides parallel current paths, compensating for the increased path length in bridge portions and maintaining overall low resistance.
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 design enhances the reliability of battery busbar connections by absorbing vibrations, improving soldering quality, and reducing the number of soldering processes required, while also providing a fuse-like function to prevent short-circuit accidents, thus increasing safety and manufacturing efficiency.
Implementation Method 1
the bridge portions which are connected between the terminal contact portions and the conductive sheet can act as a vibration buffer to absorb vibration caused by an external force
Implementation Method 2
the bridge portions, which are connected to different sides of the cavity portion, thus an electric current path on the battery busbar between the terminal contact portions is increased. This increases the resistance on the battery busbar between the soldering points
Data Source
AI summary
The disclosure provides a battery busbar including a conductive sheet, at least two bridge portions and at least two terminal contact portions. The conductive sheet has at least one cavity portion. Each of the at least two bridge portions has a first end and a second end which are opposite to each other, and the first ends of the bridge portions are respectively connected to different sides of the at least one cavity portion. The terminal contact portions are spaced apart from each other and are respectively connected to the second ends of the bridge portions. A width direction is defined to be substantially perpendicular to a line passing through the first end and the second end of one of the at least two bridge portions; along the width direction, a width of the bridge portion is smaller than a width of the terminal contact portion.