Cylindrical Battery Busbar Assembly for Quick-Charge Current Balancing
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Solution Overview
Problem
The existing cylindrical power battery modules face challenges with space occupation and reliability due to the need for numerous wire harnesses for signal collection and the requirement for thick busbars to handle high overcurrent during quick charging, leading to complex assembly processes and increased labor costs.
Innovation Solution
A busbar assembly comprising input and output copper bars and a cell contact system with conductive units connected in parallel and series, reducing current per cell unit and allowing for thinner connection pieces, which improves energy density and manufacturing efficiency while ensuring high reliability and space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire harnesses are used to connect FPC, NTC thermistor and BMS for signal collection, then voltage and temperature signals can be collected, but a relatively large number of wire harnesses occupy a large space and the assembly process becomes complicated with increased labor costs
Solution Approach 1:
The patent merges the functions of voltage signal collection and temperature signal collection into a single integrated structure. The busbar serves dual purposes: as an electrical connection component for voltage collection and as a mounting structure for temperature sensors, eliminating the need for separate wire harnesses and reducing assembly complexity
Solution Approach 2:
The busbar is designed with multi-functionality, serving as both an electrical conductor for voltage signal collection and a structural support for temperature sensor mounting. This universal component replaces multiple specialized components (wire harnesses, mounting brackets), simplifying the overall system
2Power
If the busbar is set to be relatively thick to satisfy high overcurrent capacity for quick charging, then overcurrent capacity is improved, but the busbar occupies a relatively large space
Solution Approach 1:
The patent segments the current collection function across multiple busbars instead of relying on a single thick busbar. By using multiple thinner busbars in parallel, the system achieves the required total current capacity while reducing the space occupation of each individual busbar and improving heat dissipation
3Reliability
If multiple wire harnesses are used for connecting cell units, then electrical connection is achieved, but the assembly process becomes complicated and labor costs increase
Solution Approach 1:
The patent combines multiple electrical connection functions into a single busbar component. The busbar integrates voltage collection, temperature monitoring, and structural support functions, reducing the number of separate connection components from multiple wire harnesses to a single integrated busbar, thereby dramatically improving assembly efficiency
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 balanced current distribution across cell units, supports high-rate quick charging, reduces manufacturing costs, and enhances the energy density and reliability of the cylindrical power battery module with a simpler internal structure.
Implementation Method 1
the multiple conductive units are connected in parallel to cell units disposed adjacently in the first direction, and the multiple conductive units are connected in series to cell units disposed adjacently in a second direction
Data Source
AI summary
Provided are a busbar assembly and a cylindrical power battery module. The busbar assembly is used for electrical connection of a cylindrical power battery module. The cylindrical power battery module includes an input copper bar, an output cooper bar and a cells contact system assembly having the corresponding number as submodules. The input copper bar is connected to a cell unit at an input terminal of the cylindrical power battery module, the output copper bar is connected to a cell unit at an output terminal of the cylindrical power battery module, and the cells contact system assemblies are connected in series and in parallel to cell units of the submodules.