Detachable Busbar Connection for Battery Cell Terminal Joining

Solution Overview

Problem

The welding process for connecting busbars to battery cells is complex, inefficient, and prone to poor connections, leading to reduced yield and safety risks due to undetected false welds.

Innovation Solution

A detachable connecting unit with positive and negative connecting parts that sleeve onto the battery cell terminals, simplifying the connection process and improving production efficiency and yield.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If welding process is used to connect busbar and battery cell terminals, then electrical connection is achieved, but the process becomes complicated and production efficiency decreases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidproduction efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces the welding process (thermal/mechanical system) with a mechanical pressing system. The connecting unit includes a pressing component that applies mechanical force to clamp the busbar against the battery terminal, achieving electrical connection without welding. This substitution eliminates the complex welding process while maintaining reliable electrical connection, directly resolving the contradiction between connection reliability and production efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If welding process is used to connect busbar and battery cell terminals, then electrical connection is achieved, but the process becomes complicated and device complexity increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidconnection process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the welding process (thermal/mechanical system) with a mechanical pressing system. The connecting unit includes a pressing component that applies mechanical force to clamp the busbar against the battery terminal, achieving electrical connection without welding. This substitution eliminates the complex welding process while maintaining reliable electrical connection, directly resolving the contradiction between connection reliability and production efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The connecting unit is divided into separate functional components: a connecting body, a pressing component, and a limiting component. This segmentation allows each component to perform its specific function independently, simplifying the overall device structure and making assembly/disassembly easier, thereby reducing device complexity while ensuring reliable connection.

Inventive Principle:

Principle #1Segmentation

3Reliability

If welding process is used to connect busbar and battery cell terminals, then electrical connection is achieved, but poor welding occurs affecting yield rate

Engineering Contradiction:

Improvewelding qualityVSAvoidyield rate

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces the welding process (thermal/mechanical system) with a mechanical pressing system. The connecting unit includes a pressing component that applies mechanical force to clamp the busbar against the battery terminal, achieving electrical connection without welding. This substitution eliminates the complex welding process while maintaining reliable electrical connection, directly resolving the contradiction between connection reliability and production efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The connecting unit acts as an intermediary component between the busbar and the battery terminal. It provides a standardized interface that ensures proper alignment and contact, eliminating the variability and quality issues associated with direct welding. The limiting component within the connecting unit further mediates the connection by controlling the position and orientation, ensuring consistent connection quality and high yield rate.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP4579925A1Connecting unit, busbar, and battery module

Publication Date: 2025.07.02 EVE ENERGY CO LTD

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AI summary

The present disclosure provides a connecting unit, a busbar (200), and a battery module (300). The connecting unit is configured to connect battery cells (100). The battery cells (100) include at least a first battery cell (11) and a second battery cell (12). The connecting unit includes a first positive connecting part (21) configured to detachably connect a positive terminal (111) of the first battery cell (11) and electrically connected to the positive terminal (111) of the first battery cell (11); and a first negative connecting part (31) configured to detachably connect a negative terminal (133) of the second battery cell (13) and electrically connected to the negative terminal (133) of the second battery cell (13). The first negative connecting part (31) is connected to the first positive connecting part (21).