Busbar Module Interlocking Battery Cell Connections
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Solution Overview
Problem
Existing methods for connecting battery cells in series face challenges with weldability between different metal electrode terminals, leading to weakened bonding strength and safety risks due to exposure of conductive busbars, particularly when using laser welding with aluminum and copper terminals.
Innovation Solution
A busbar module with a conductive busbar and insulating portion that includes guide portions and a spacer for sliding engagement with electrode terminals, preventing exposure and ensuring secure connections without weldability issues between different metals, while maintaining a predetermined interval for ventilation and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If laser welding is used to connect busbar with aluminum and copper electrode terminals, then electrical connection is achieved, but weldability deteriorates and bonding strength weakens due to incompatibility between different metals
Solution Approach 1:
The patent introduces a busbar with insulating coating as an intermediary component between aluminum and copper electrode terminals. The insulating coating prevents direct contact between dissimilar metals, eliminating weldability issues while maintaining electrical connection through conductive contact. This mediator approach resolves the contradiction by allowing connection of different metals without requiring them to be welded directly to each other.
Solution Approach 2:
The patent replaces the laser welding mechanical system with a sliding insertion mechanism. Instead of using laser welding to join the busbar to electrode terminals, the busbar is designed with sliding portions that insert into corresponding grooves on the terminals. This mechanical substitution eliminates the weldability problem entirely by avoiding the welding process for dissimilar metals.
2Reliability
If busbar is exposed for electrical connection, then electrical conductivity is improved, but safety deteriorates due to risk of external exposure and short circuit
Solution Approach 1:
The patent applies an insulating coating (thin film) on the busbar surface to provide electrical insulation while maintaining the conductive function. The insulating coating covers the busbar body, preventing external exposure and short circuit risks, while the sliding portions maintain electrical connection through controlled contact points. This resolves the contradiction by providing both safety through insulation and conductivity through designated contact areas.
Solution Approach 2:
The busbar is segmented into different functional zones: insulating coated portions for safety and sliding portions for electrical connection. This segmentation allows different parts of the same component to serve different functions - the insulating coating provides safety by preventing external exposure, while the sliding portions maintain electrical conductivity. This resolves the contradiction by spatially separating the safety and conductivity functions.
3Power
If battery cells are connected in series with busbar, then voltage is increased, but device complexity increases due to alignment and positioning requirements
Solution Approach 1:
The busbar design incorporates self-aligning sliding portions that automatically fit into corresponding grooves on the electrode terminals during assembly. This self-service mechanism eliminates the need for complex external alignment tools or procedures. The sliding portions are designed with specific geometries that guide them into the correct positions, allowing the system to self-align and reducing assembly complexity while maintaining the series connection for voltage increase.
Solution Approach 2:
The busbar sliding portions are pre-formed with specific shapes that match the grooves on the electrode terminals before assembly. This preliminary action of pre-shaping the connection interfaces simplifies the assembly process, as the components are designed to fit together without requiring complex alignment procedures during installation. This reduces device complexity while enabling series connection for voltage increase.
Data Source
AI summary
A busbar module connects a first cell and a second cell adjacent to the first cell, arranged in a first direction and each having first and second electrode terminals spaced apart in a second direction normal to the first direction. The busbar module includes a busbar that electrically connects a first electrode terminal of the first cell and a second electrode terminal of the second cell to each other, and an insulating portion that accommodates the busbar. The busbar includes a first recessed mounting portion, the first recessed mounting portion and a protruding shape of the first electrode terminal having interfitting shapes and a second recessed mounting portion, the second recessed mounting portion and a protruding shape of the second electrode terminal having interfitting shapes, the first and second mounting portions, being slideably coupleable with the first and second electrode terminals.