Battery Busbar Layout for Irregular Cell Connections
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Solution Overview
Problem
Existing battery connection technologies are inadequate for connecting more than a certain number of batteries irregularly arranged, as they cannot maintain regular and symmetric positions, limiting their applicability when connecting multiple batteries.
Innovation Solution
A battery connection module comprising a tray and multiple connecting busbars, where each busbar has components with main body portions, positive and negative electrode connecting portions, and fusible portions for overcurrent protection, allowing connection of irregularly arranged battery cells by staggering them in rows and columns for a regular symmetric arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If symmetric and regular arrangement of tab connecting points is used, then manufacturing precision and structural stability are improved, but adaptability to connect irregularly arranged batteries deteriorates
Solution Approach 1:
The patent applies asymmetry by designing busbars with asymmetric tab connecting point arrangements that do not follow symmetric patterns. The busbars have connecting points positioned at irregular intervals and asymmetric locations to match the asymmetric arrangement of battery tabs, enabling connection of batteries in irregular configurations while maintaining manufacturing precision through standardized asymmetric busbar designs
Solution Approach 2:
The patent implements universality by creating a standardized busbar component that can connect multiple batteries (more than two columns) with various asymmetric arrangements. The busbar design incorporates multiple tab connecting points with different configurations that can adapt to different battery layouts, making a single busbar type capable of serving multiple connection scenarios and reducing the need for custom-designed busbars for each configuration
2Device complexity
If one electrical conduction piece connects only two adjacent columns of batteries, then device complexity is reduced, but productivity and connection capacity deteriorate
Solution Approach 1:
The patent applies merging by integrating multiple connection functions into a single busbar component. The busbar is designed with multiple tab connecting points that can simultaneously connect three or more columns of batteries, combining what would traditionally require multiple separate conduction pieces into one unified component, thereby increasing connection capacity while managing complexity through standardization
Solution Approach 2:
The patent uses segmentation by dividing the busbar into multiple functional sections, each with tab connecting points for connecting to different battery columns. The busbar body is segmented into regions that interface with different battery arrangements, allowing each section to be optimized for its specific connection task while maintaining overall structural integrity and enabling connection of multiple batteries through a single integrated component
Data Source
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AI summary
A battery connection module is provided, the battery connection module includes a tray and a plurality of connecting busbars; the plurality of connecting busbars are assembled on the tray; each connecting busbar has a plurality of components, each of a part of the plurality of components having a main body portion, a positive electrode connecting portion which extends from a first end of the main body portion and a negative electrode connecting portion which extends from a second end of the main body portion, each of a part of the plurality of components has a main body portion and only has a positive electrode connecting portion which extends from a first end of the main body portion, each of a part of the plurality of components has a main body portion and only has a negative electrode connecting portion which extends from a second end of the main body portion; the main body portions of the plurality of components of each connecting busbar are integrally connected by respective connection portions; in each the connecting busbar, each of a part of the plurality of components connects the positive electrodes and the negative electrodes of the two battery cells of every other column, each of a part of the plurality of components connects the positive electrodes and the negative electrodes of the two battery cells of the same row, each of a part of the plurality of components only connects the positive electrode of one the battery cell, each of a part of the plurality of components only connects the negative electrode of one the battery cell.