Bent Busbar Folding Line to Prevent Current Bottlenecks
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Solution Overview
Problem
Conventional busbars in secondary batteries experience excessive heat generation due to reduced cross-sectional area from notch parts, leading to potential damage and safety issues like fire or explosion, and lack efficient coupling in limited spaces.
Innovation Solution
A high voltage busbar design with a bendable structure and a folding line within the body connector to maintain a consistent cross-sectional area, ensuring stable current transmission and efficient coupling with electrode tabs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a notch part is formed at the boundary area of the bent part to ensure easy bending forming, then the bending formability is improved, but the cross-sectional area is reduced causing excessive heat generation
Solution Approach 1:
The busbar is divided into a body connection part and a bent connection part with a clear boundary. The folding line is positioned within the body connection part at a predetermined distance from the side edge, creating a segmented structure that allows bending without compromising the cross-sectional area of the current path.
Solution Approach 2:
Different parts of the busbar have different functional qualities: the body connection part maintains a consistent cross-sectional area for stable current transmission, while the bent connection part is designed for flexible coupling. The folding line is locally positioned to enable bending without affecting the overall cross-sectional integrity.
2Adaptability or versatility
If the busbar is made bendable to accommodate limited space, then the adaptability is improved, but the cross-sectional area reduction causes electrical resistance increase
Solution Approach 1:
The folding line is positioned within the body connection part rather than at the edge, creating a three-dimensional bending configuration. This dimensional adjustment allows the bent connection part to achieve flexibility while the body connection part maintains its cross-sectional area for reliable current transmission.
Solution Approach 2:
The folding line acts as an intermediary element that enables bending flexibility. By positioning it within the body connection part at a predetermined distance from the side edge, it mediates between the need for bendability and the requirement for maintaining cross-sectional area integrity.
3Ease of operation
If the folding line is positioned at the side edge for maximum bending flexibility, then the ease of operation is improved, but the current transmission stability deteriorates
Solution Approach 1:
The folding line is preliminarily positioned within the body connection part at a predetermined distance from the side edge during the design stage. This preliminary positioning ensures that bending can be easily performed while preventing bottlenecks in the current path, thus maintaining current transmission stability.
Solution Approach 2:
The folding line is asymmetrically positioned within the body connection part rather than at the center or edge. This asymmetric positioning optimizes both bending ease and current transmission stability by creating sufficient distance from the side edge to prevent bottlenecks while maintaining flexibility.
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
Prevents electric current bottlenecks and maintains consistent resistance, enhancing stability and reliability of battery modules by allowing flexible bending without notches, thus preventing heat-related damage.
Implementation Method 1
electric current may be transmitted stably between the body connection part and the bent connection part without an electric current bottleneck phenomenon
Data Source
AI summary
According to an embodiment, there is provided a busbar having a bent shape is proposed. The busbar includes: a body connector having a plate shape configured to electrically connect a plurality of battery cells to each other; and a bent connector branched outwardly from a side edge of the body connector and electrically connected to an external component. The bent connector starts to bend on the basis of a folding line positioned therein with a predetermined distance from the side edge of the body connector, so that current may be stably transmitted between the body connector and the bent connector without an electric current bottleneck phenomenon. According to an embodiment, there is also provided a battery module for secondary batteries, the battery module including the bent-shaped busbar.