Battery Busbar Clamping Structure to Reduce Welding Points
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Solution Overview
Problem
The existing busbar connection methods in cylindrical battery modules require extensive welding, leading to low production efficiency and a high risk of welding failures due to the large number of welding spots.
Innovation Solution
A conductive member with a first connection body and a second connection body that clamp the outer peripheral side of one battery cell and the pole of the adjacent battery cell, respectively, reducing the need for welding and improving connection efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resistance welding or laser welding is used to connect busbar to battery cells, then reliable electrical connection is achieved, but the large number of welding spots increases production time and reduces manufacturing efficiency
Solution Approach 1:
The conductive member is divided into multiple connection bodies (first connection body and second connection body) that can independently clamp adjacent battery cells. This segmentation allows parallel connection of multiple cells, reducing the sequential welding operations and improving manufacturing efficiency while maintaining reliable electrical connections through each clamping interface.
Solution Approach 2:
The invention replaces the welding process (thermal/chemical joining) with a mechanical clamping system. The connection bodies clamp the battery cell housings and poles mechanically, establishing electrical connection through conductive contact without requiring welding operations. This substitution eliminates welding spots, reduces production time, and maintains connection reliability through secure mechanical engagement.
2Reliability
If both positive and negative electrodes of each battery cell are welded to conductive members on the busbar, then proper electrical connection is established, but the workload increases and production efficiency decreases
Solution Approach 1:
The first connection body and second connection body are integrated into a single conductive member structure, combining multiple connection functions into one component. This merging allows simultaneous clamping of adjacent battery cells while maintaining electrical continuity, reducing the number of separate operations and assembly time compared to traditional welded busbar configurations.
Solution Approach 2:
The conductive member serves multiple functions: it provides electrical connection for both positive and negative electrodes, mechanically supports adjacent battery cells, and establishes connectivity across multiple cells simultaneously. This multi-functionality reduces the overall workload and assembly time compared to dedicated welded connections for each electrode.
Data Source
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AI summary
A conductive member includes a first connection body and a second connection body connected to the first connection body. The first connection body is configured to be clamped with an outer peripheral side of one cell of two adjacent battery cells. The second connection body is configured to be in contact with a pole of the other cell of the two adjacent battery cells. The conductive member is clamped with the outer peripheral side of the battery cell through the first connection body. The busbar is configured to clamp the conductive member with the outer peripheral side of the battery cell through the first connection body.