Busbar Strap Layout for Uniform Battery Cell Resistance
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Solution Overview
Problem
Existing battery pack designs face challenges in maintaining uniform electrical resistance across multiple battery cells, leading to temperature differences and potential performance issues due to varying pathway lengths and resistances in busbar straps.
Innovation Solution
The use of a busbar strap with multiple battery connection plates and electrical pathways, where each pathway has a resistance within a specific percentage of the others, ensuring balanced electrical flow and reduced temperature variations across cells, is achieved by strategically placing battery connection plates and using electrical bypasses to equalize resistances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a busbar strap connects to battery cells at different positions along its length, then electrical connection is achieved, but pathway resistance varies across cells causing temperature differences
Solution Approach 1:
The busbar strap is designed with equal length path portions extending from the battery connection plate to both ends of the strap, ensuring that electrical pathways to cells at different positions have equal resistance. This equipotential design equalizes current distribution and eliminates temperature differences caused by resistance variations.
2Adaptability or versatility
If battery connection plates are positioned at different locations on the busbar strap, then all cells can be connected, but pathway lengths and resistances become unequal
Solution Approach 1:
The busbar strap incorporates equal length path portions that extend from the battery connection plate to both ends of the strap, ensuring that despite cells being connected at different locations, the electrical pathway resistance remains equal for all cells. This design maintains manufacturing precision while enabling multi-cell connection capability.
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
This solution ensures that the largest pathway resistance is within a controlled percentage of the smallest, minimizing temperature differences between cells and enhancing overall battery pack performance and efficiency.
Implementation Method 1
an electrical pathway that extends between the current collection tab and the battery connection plate, the electrical pathway includes a first path portion that extends between the current collection tab and an area past the battery connection plate and a second path portion that extends between the area past the battery connection plate and the battery connection plate
Data Source
AI summary
A battery pack may include a positive pack terminal, a negative pack terminal, a cell assembly, a busbar strap, and an electrical pathway. The cell assembly includes battery cells. The busbar strap has a current collection tab and a battery connection plate. The battery connection plate is electrically connected to the battery cell closest to the current collection tab. The electrical pathway extends between the current collection tab and the battery connection plate. The electrical pathway includes a first path portion that extends between the current collection tab and an area past the battery connection plate and a second path portion that extends between the area past the battery connection plate and the battery connection plate.