Battery Sampling Busbar with Interlocking Bent Connecting Sheet
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Solution Overview
Problem
Current battery module sampling methods, particularly those using connecting sheets, face challenges in ensuring strong connections between the connecting sheet and busbar, leading to increased process complexity, reduced production efficiency, and higher costs.
Innovation Solution
A sampling component with a busbar featuring mounting slots and a connecting sheet with a bent portion that fits into these slots, enhancing the connection strength and stability between the connecting sheet and busbar without affecting its connection to the circuit board, and increasing the contact area for improved overload capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding strength is increased to ensure connection between connecting sheet and busbar, then connection strength is improved, but process complexity increases and production efficiency decreases
Solution Approach 1:
The connecting sheet incorporates a bent portion with a curved configuration that fits into the mounting slot of the busbar. This curvature enables mechanical interlocking between the connecting sheet and busbar, providing strong connection without requiring increased welding strength, thus maintaining production efficiency while achieving reliable electrical connection.
2Strength
If welding of other components is used to ensure connection strength, then connection strength is improved, but device complexity and cost increase
Solution Approach 1:
The connecting sheet is divided into distinct functional portions: a first flat portion for connection to the circuit board, a bent portion for insertion into the busbar's mounting slot, and a second flat portion for additional support. This segmentation allows each portion to perform its specific function optimally, achieving strong connection through the bent portion's mechanical interlocking without requiring additional welding components.
Solution Approach 2:
The connection mechanism transitions from a two-dimensional planar connection to a three-dimensional interlocking structure. The bent portion extends in the thickness direction of the busbar and engages with the mounting slot, creating a spatially distributed connection that enhances mechanical strength and electrical contact without adding structural complexity.
3Strength
If mounting slots are added to the busbar for the bent portion, then connection strength is improved, but manufacturing complexity increases
Solution Approach 1:
The mounting slots are pre-formed on the busbar during the busbar manufacturing process, before assembly with the connecting sheet and circuit board. This preliminary action allows the slots to be integrated into the busbar's structure, and the connecting sheet's bent portion is simply inserted into these pre-prepared slots during assembly, achieving strong connection without complex manufacturing steps.
Data Source
AI summary
Embodiments of the present invention provide a sampling component and a battery module. The sampling component is applied to a battery module and comprises: a busbar having a first surface and a second surface which are opposite to each other, the busbar comprising mounting slots formed by extending in a direction from the first surface to the second surface; a circuit board disposed on a side of the busbar; and, a connecting sheet, comprising a first flat portion and a bent portion which are connected to each other, one end of the first flat portion being connected to the busbar while the other end thereof being connected to the circuit board, the bent portion being located in the mounting slots.