Integrated Busbar Structure with Folded Side Edges for Heat Dissipation

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Solution Overview

Problem

Existing busbar structures for electric storage devices require separate parts for fuse and inter-battery connection functions, leading to increased part numbers and potential temperature rise issues when connecting multiple batteries.

Innovation Solution

A busbar structure with an electrode connection portion having a fuse function and an inter-battery connection portion that includes an extended body with folded side edge portions, allowing both functions to be integrated into a single part, enhancing material utilization and heat dissipation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the fuse portion and the inter-battery connection portion are provided as separate parts with different thickness, then both the fuse function and the inter-battery connection function can be realized, but the number of parts is remarkably increased

Engineering Contradiction:

Improvefunctional capabilityVSAvoidnumber of parts

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines the fuse portion and the inter-battery connection portion into a single integrated busbar structure. The busbar has a first portion with smaller cross-sectional area for fuse function and a second portion with larger cross-sectional area for inter-battery connection, both formed as one continuous piece through extrusion or rolling processes, thereby reducing the number of parts while maintaining both functions

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The busbar is designed to perform multiple functions within a single component: it serves as both a protective fuse element (first portion with smaller cross-section) and an inter-battery connection conductor (second portion with larger cross-section). This multi-functional design eliminates the need for separate fuse and connection parts

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If the busbar has thin thickness to satisfy the fuse characteristic, then the fuse function is achieved, but the temperature rises when current is applied

Engineering Contradiction:

Improvefuse functionVSAvoidtemperature rise

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The busbar employs local quality variation by having different cross-sectional areas in different portions: the first portion has a smaller cross-sectional area optimized for fuse characteristics (thin enough to melt at rated current), while the second portion has a larger cross-sectional area optimized for heat dissipation and current carrying capacity. Each portion is locally optimized for its specific function

Inventive Principle:

Principle #3Local quality

3Temperature

If the busbar has thick thickness to prevent temperature rising, then the inter-battery connection function is improved, but the fuse characteristic is not satisfied

Engineering Contradiction:

Improvetemperature stabilityVSAvoidfuse characteristic

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

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

Enables both fuse and inter-battery connection functions without increasing the number of parts, improving assemblability and reducing temperature rise by securing a larger cross-sectional area and surface area for heat radiation.

Implementation Method 1

the surface area is also large, and thus the amount of heat radiation can also be increased

Methodology Applied

Scientific EffectHeat radiation: Thermal Radiation

Implementation Method 2

it is desirable to reduce the thickness in the fuse shape of the busbar as the connecting conductor to satisfy the fusing characteristic

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS10581054B2Busbar structure

Publication Date: 2020.03.03 YAZAKI CORP

AI summary

A busbar structure includes an electrode connection portion that is made of conductive metal and includes a terminal portion and an inter-battery connection portion that has an extended body portion extending from the electrode connection portion and at least one side edge portion of a pair of side edge portions extending from both ends of the extended body portion in a width direction perpendicular to an extending direction of the extended body portion. The at least one side edge portion of the pair of side edge portions is folded onto the extended body portion.