Battery Module Busbar Joint Structure for Lower Resistance Heat
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Solution Overview
Problem
The high resistance and heat generation of existing conductive sheets in battery modules restrict the performance of battery packs, particularly as current demands increase.
Innovation Solution
The battery module design includes a body with a first conductive sheet and an electrode base, connected to a second conductive sheet with a groove structure and a conductive block, which increases contact area and reduces resistance and heat generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a conventional conductive sheet is used to connect battery modules, then the structure is simple, but the resistance is high and heat generation is excessive
Solution Approach 1:
The conductive sheet is segmented into a first conductive sheet and a second conductive sheet, which are connected through a conductive block. This segmentation allows for optimized current distribution and reduced resistance at connection points, thereby reducing heat generation while maintaining structural manageability.
Solution Approach 2:
The first conductive sheet is inserted into a groove of the second conductive sheet, creating a nested structure. This nesting design increases the contact area between conductive sheets and provides multiple contact points, reducing resistance and heat generation without significantly increasing overall structural complexity.
2Reliability
If the contact area between conductive sheets is increased, then resistance is reduced, but the structural complexity increases
Solution Approach 1:
The first conductive sheet is inserted into a groove of the second conductive sheet, creating a nested structure that naturally increases contact area. This nested design achieves improved current transfer efficiency and reliability while adding minimal structural complexity, as the groove and insertion geometry are straightforward to manufacture.
Solution Approach 2:
The conductive block is positioned at the connection interface between the first and second conductive sheets, adding a third dimensional element to the connection. This dimensional addition creates multiple contact points and increases effective contact area, improving reliability without requiring complex planar expansions.
3Loss of energy
If a conductive block is added to increase cross-sectional area, then resistance is reduced, but the device complexity increases
Solution Approach 1:
The conductive block is introduced as a separate segmented element that connects the first and second conductive sheets. This segmentation allows the conductive block to be independently optimized for electrical conductivity and mechanical fit, reducing resistance and heat generation while keeping the overall assembly manageable through modular construction.
Solution Approach 2:
The conductive block is nested within the groove structure where the first conductive sheet inserts into the second conductive sheet. This nesting positions the conductive block precisely at the critical connection interface, maximizing its effectiveness in reducing resistance and heat generation without adding excessive structural complexity.
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 improved contact area and reduced resistance enhance current transfer efficiency between battery modules, while the conductive block further reduces heat generation and improves reliability.
Implementation Method 1
a surface of the second conductive sheet has a fusible layer, the fusible layer melting when a temperature reaches a preset temperature
Implementation Method 2
the fusible layer being made of tin or nickel, and the fusible layer being formed on the surface of the second conductive sheet by electroplating
Implementation Method 3
reduces resistance of a path through which a current flows between battery modules, and reduces an amount of heat generated by the second conductive sheet when the current flows through the second conductive sheet
Data Source
AI summary
Battery module and battery pack are provided. Battery module includes: body and second conductive sheet. Body has first conductive sheet and electrode base. Second conductive sheet has one end connected to first conductive sheet and fixed to electrode base and other end configured to be connected to adjacent battery module. Second conductive sheet is provided with first groove, first conductive sheet extends into first groove, and conductive block is further provided between first groove and first conductive sheet. First conductive sheet extends into first groove, which increases contact area between first and second conductive sheets, reduces resistance among battery modules, reduces amount of heat from second conductive sheet, and improves efficiency of transfer of current among battery modules. Conductive block is provided between first groove and first conductive sheet, which increases cross-sectional area at junction between second and first conductive sheets, and further reduces resistance among battery modules.