Busbar Assembly Butt-Weld Structure for Battery Module Current Flow
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing welding structures for busbar assemblies in battery modules are affected by the thickness of the busbar, leading to potential issues with current passage and thermal deformation, limiting design flexibility and material selection.
Innovation Solution
A new welding structure using butt welding between the busbar plate and terminal, with specific thickness configurations and additional features like terminal leads and frames, to enhance current passage and reduce thermal deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional welding structures are used for busbar assemblies, then the busbar can be connected to the terminal, but the cross-sectional area for current passage is limited and thermal deformation occurs during welding
Solution Approach 1:
The busbar is divided into a plate portion and a protruding portion with different thicknesses. The plate portion has greater thickness to provide a larger cross-sectional area for current passage, while the protruding portion extends toward the terminal for welding. This segmentation allows each part to serve its specific function optimally without requiring the entire busbar to have uniform increased thickness.
Solution Approach 2:
The busbar is designed with non-uniform thickness distribution - the plate portion has greater thickness for current conduction, while the protruding portion has reduced thickness for welding compatibility. This local quality variation optimizes both current passage capability and welding performance without compromising either function.
2Reliability
If busbar thickness is increased to improve current passage, then current carrying capacity improves, but welding becomes more difficult and thermal deformation increases
Solution Approach 1:
The busbar is segmented into a thick plate portion for current conduction and a thinner protruding portion for welding. This allows the current-carrying section to have sufficient thickness while the welding section maintains optimal thickness for easy welding and reduced thermal deformation.
Solution Approach 2:
Different sections of the busbar have different thickness qualities - the plate portion has greater thickness for current capacity, while the protruding portion has reduced thickness for welding ease. This local variation in quality resolves the contradiction between current carrying capacity and welding ease.
3Ease of manufacture
If uniform thickness busbar is used, then manufacturing is simpler, but design flexibility for optimizing both current passage and welding is limited
Solution Approach 1:
The busbar is segmented into functional portions with different thicknesses - the plate portion and the protruding portion. This segmentation provides design flexibility to optimize current passage in the plate portion while ensuring welding compatibility in the protruding portion, without significantly complicating the manufacturing process.
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 new welding structure increases the cross-sectional area for current passage, reduces thermal deformation, and provides greater design freedom for busbar thickness and material selection.
Implementation Method 1
the welding portion may be formed by butt welding between the busbar plate and the busbar terminal
Data Source
AI summary
The busbar assembly of the present disclosure comprises a busbar plate electrically connected to electrode tabs of a plurality of battery cells; a busbar terminal electrically connected to an external device; and a welding portion electrically connecting the busbar plate and the busbar terminal with each other, wherein the welding portion is formed by butt welding between the busbar plate and the busbar terminal.