Clamping Busbar Structure to Cut Battery Cell Welding Spots
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Solution Overview
Problem
The production efficiency of cylindrical battery modules is low due to the large number of welding spots required to connect the positive and negative electrodes of each battery cell to conductive members on the busbar, increasing the risk of welding failure and reducing production quality.
Innovation Solution
A conductive member with a first connection body and a second connection body is designed to clamp the outer peripheral side of one battery cell and contact the pole of the adjacent battery cell, respectively, reducing the number of welding spots and improving connection efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resistance welding or laser welding is used to connect battery cells to busbar conductive members, then reliable electrical connection is achieved, but the number of welding spots increases significantly, reducing production efficiency and increasing welding failure risk
Solution Approach 1:
The patent merges the functions of multiple separate conductive members into a single integrated busbar structure. The busbar includes a first conductive member connected to the first battery cell and a second conductive member connected to the second battery cell, which are integrated into one piece. This consolidation reduces the number of welding spots from multiple separate connections to fewer unified connections, thereby improving production efficiency while maintaining reliable electrical connections.
Solution Approach 2:
The busbar structure serves multiple functions simultaneously: it provides electrical connection for both the first and second battery cells, acts as a structural support element, and enables series or parallel connection configurations. The first and second conductive members of the busbar can connect to different terminals (positive or negative) of different battery cells, providing universal connectivity that reduces the overall number of welding operations required.
2Adaptability or versatility
If hundreds or thousands of battery cells are connected in series and parallel through multiple welding spots, then the desired electrical configuration is achieved, but the workload increases and production quality deteriorates
Solution Approach 1:
The busbar is segmented into functional sections (first conductive member and second conductive member) that can be independently configured for different connection types. Each conductive member can be designed with specific geometries and connection points to accommodate series or parallel connections, allowing flexible electrical configurations while maintaining controlled, reduced welding spot counts that preserve manufacturing precision and production quality.
Data Source
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.