Clad Plate Bus Bar Impedance Balancing for Voltage Detection
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Solution Overview
Problem
Existing power supply devices with bus bars made of single or clad metal materials face measurement errors in battery cell voltage detection due to varying electric resistances, leading to inaccurate voltage readings and potential corrosion issues when different metal materials are used for electrode terminals.
Innovation Solution
The use of bus bars formed with clad plates of different metal materials, where the impedance between terminal holding portions and tab holding portions is made equal, along with specific design features such as varying widths and thicknesses, to compensate for conductivity differences and stabilize voltage detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If bus bars are made of single metal material (copper or aluminum), then manufacturing is simple and cost is low, but voltage detection precision is poor due to varying electric resistance along the bus bar length
Solution Approach 1:
The bus bar is segmented into multiple metal portions (first metal portion and second metal portion) with different materials arranged in sequence along the length direction. This segmentation allows different sections to have different electrical properties, compensating for voltage detection errors caused by resistance variations along the bus bar.
Solution Approach 2:
Different portions of the bus bar are assigned different metal materials (e.g., copper in the first portion, aluminum in the second portion) to create local variations in electrical conductivity. This local quality differentiation enables precise compensation for voltage detection errors at specific locations along the bus bar.
2Measurement precision
If bus bars are made of clad plate with different metal materials, then voltage detection precision is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The bus bar is constructed as a composite structure using clad plate technology, where different metal materials (copper and aluminum) are bonded together in a layered configuration. This composite structure achieves both improved voltage detection precision and acceptable manufacturing feasibility through established clad plate fabrication processes.
3Adaptability or versatility
If different metal materials are used for electrode terminals, then adaptability to different battery cell types is improved, but corrosion resistance deteriorates due to galvanic corrosion between dissimilar metals
Solution Approach 1:
The multi-material bus bar structure acts as an intermediary between battery cells with different electrode terminal materials. By strategically arranging copper and aluminum portions, the bus bar provides galvanic isolation, preventing direct contact between dissimilar metals and eliminating galvanic corrosion while maintaining electrical connectivity.
4Power
If the number of battery cells is increased to raise power output, then power capability is improved, but voltage detection accuracy deteriorates due to increased bus bar length and resistance variations
Solution Approach 1:
The bus bar is segmented into multiple metal portions (first metal portion and second metal portion) with different materials arranged in sequence along the length direction. This segmentation allows different sections to have different electrical properties, compensating for voltage detection errors caused by resistance variations along the bus bar.
Solution Approach 2:
Different portions of the bus bar are assigned different metal materials (e.g., copper in the first portion, aluminum in the second portion) to create local variations in electrical conductivity. This local quality differentiation enables precise compensation for voltage detection errors at specific locations along the bus bar.
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 design effectively suppresses errors in battery cell voltage detection, allowing for precise voltage measurement and preventing corrosion by ensuring stable contact between bus bars and electrode terminals, even when different metal materials are used.
Implementation Method 1
The bus bar is formed of a clad plate that is formed of a first metal portion and a second metal portion the material of which is different from the first metal portion
Implementation Method 2
the impedance between the first terminal holding portion and the tab holding portion is substantially equal to the impedance between the tab holding portion and the second terminal holding portion
Implementation Method 3
preventing corrosion by ensuring stable contact between bus bars and electrode terminals, even when different metal materials are used
Data Source
AI summary
A power supply device in which bars BB extend in one direction and connect the terminals of the battery cells adjacent to each other. The lines (20) are electrically connectable to the bars BB. The tabs TB electrically connect the bars BB to the lines (20). The bar BB is formed of a clad plate formed of a first metal (3A) and a second metal (3B). The bar BB includes first and second holders (3a and 3b), and a tab holder. The first and second holders (3a and 3b) are arranged in the first and second metals, respectively, and hold the terminals at holding positions. The tab holder is arranged in the first metal (3A), and holds the tab TB at a holding position. The impedance between the first holder (3a) and the tab holder is substantially equal to the impedance between the tab holder and the second holder (3b).