Battery Module Busbar Asymmetric Connection Structures
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Solution Overview
Problem
Conventional battery modules face issues with short circuits due to incorrect orientation of batteries, which can occur when stacking batteries, leading to improper connection with busbars and potential electrical shorts.
Innovation Solution
The battery module incorporates specific structures on both the batteries and busbars, such as varying heights and positions of terminals and intermediate components, to ensure correct alignment and prevent electrical connection when orientations are incorrect, thereby preventing short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If batteries are stacked together and connected with busbars, then the battery module can generate high voltage through series connection, but incorrect orientation of batteries may cause short circuits between batteries
Solution Approach 1:
The busbar is designed with asymmetric structures including a first protrusion and a second protrusion that are different in shape and position. The first battery unit has a first recess corresponding to the first protrusion, while the second battery unit has a second recess corresponding to the second protrusion. This asymmetric design ensures that only battery units with correct orientation can be properly connected to the busbar, preventing short circuits caused by incorrect stacking orientation while maintaining high voltage generation through series connection.
2Device complexity
If busbars connect multiple batteries in parallel to form battery units, then the number of components is reduced and cost is lowered, but the complexity of ensuring correct connection orientation increases
Solution Approach 1:
The asymmetric protrusion and recess design provides built-in orientation guidance that simplifies the manufacturing process. The unique shapes of the first and second protrusions with their specific positions relative to battery units make it visually and physically obvious how to correctly assemble the battery module, eliminating the need for complex orientation control procedures while maintaining component reduction benefits.
Solution Approach 2:
The busbar and battery units are designed with pre-formed protrusions and recesses that guide correct orientation before final connection. This preliminary structural arrangement ensures that during assembly, the correct orientation is naturally achieved through the fit of these features, reducing the need for additional orientation control steps in the manufacturing process.
Data Source
AI summary
A battery module includes a plurality of batteries stacked together, and a busbar. Each of the plurality of batteries includes a battery-side first structure and a battery-side second structure that regulate the connection of the battery and the busbar. The busbar has a busbar-side first structure and a busbar-side second structure that regulate the connection of the busbar and each of the batteries. If the battery-side first structures of the plurality of batteries are combined with the busbar-side first structure, and the battery-side second structures of the plurality of batteries are combined with the busbar-side second structure, each of the batteries is connected with the busbar. Alternatively, if the battery-side first structure of any one of the batteries is combined with the busbar-side second structure, the one of the batteries or another one of the batteries is not connected with the busbar.