Battery Busbar Buffer Section Absorbs Mechanical Stress
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Solution Overview
Problem
The existing series and parallel connection methods of battery cells using metal strips are prone to wrinkling or fracture due to mechanical stress, leading to circuit disruptions and reduced reliability in battery modules.
Innovation Solution
A busbar with conductive units featuring positive and negative connection regions and buffer sections to absorb mechanical stress, ensuring reliable connections between cells and reducing the risk of breakage through electrical connections and buffering mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If metal strips are used to connect cells in series and parallel, then the connection method is simple and easy to manufacture, but the metal strips are prone to wrinkling or fracture due to tension or pressure from cell shaking during use
Solution Approach 1:
The busbar is divided into multiple conductive units, each independently connecting a positive electrode and a negative electrode. This segmentation allows each unit to handle mechanical stress independently, preventing the entire connection structure from failing due to cell shaking.
Solution Approach 2:
A buffer section is specifically designed and built into the busbar structure between the positive and negative connection regions. This buffer section anticipates and absorbs the tension and pressure caused by cell shaking before it can cause wrinkling or fracture to the conductive units.
2Reliability
If rigid metal strips are used for cell connection, then the electrical connection is reliable, but the connection pieces cannot withstand the expansion forces and displacements during battery operation
Solution Approach 1:
Different parts of the busbar have different properties: the conductive units maintain rigid electrical connection properties, while the buffer section has flexible mechanical properties to absorb expansion forces and displacements during battery operation.
Solution Approach 2:
The buffer section is designed to dynamically respond to mechanical stress from cell expansion and shaking during operation, allowing the busbar to adapt to changing mechanical conditions while maintaining electrical connectivity.
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 busbar design enhances the reliability of battery connections by mitigating mechanical stress, preventing breakage, and ensuring consistent operation of battery modules by absorbing expansion forces and displacements, thereby improving the overall performance and safety of the battery pack.
Implementation Method 1
a first buffer section arranged between the positive connection region and the negative connection region
Data Source
AI summary
A busbar, a battery module, and a battery pack, including multiple conductive units; wherein each conductive unit includes a positive connection region, a negative connection region, and a first buffer section arranged between the positive connection region and the negative connection region; the positive connection region is configured to connect a positive electrode of a cell, and the negative connection region is configured to connect a negative electrode of another cell; adjacent two of the plurality of conductive units are electrically connected to each other by a connecting member. The above design can realize the series and parallel connection of cells, which can have a certain buffering effect, avoid the busbar from breaking, improve the reliability of the operation of the busbar, and ensure the reliability of the connection between the cells and the busbar.