Flexible Busbar Layout for Adjustable Battery Cell Positioning
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Solution Overview
Problem
Lithium-ion batteries face challenges in adjusting the relative position of battery cells due to their rigid electrical connection structure, which limits adaptability to different vehicle mounting spaces, reducing production efficiency and assembly flexibility.
Innovation Solution
A busbar component with a flexible bend portion is introduced, allowing for adjustable connection between battery cells, enabling varying distances and angles to match specific vehicle mounting requirements, while maintaining conductivity and avoiding contact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If battery cells are connected by welding with a rigid busbar component, then electrical connection between battery cells is achieved, but the relative position between battery cells becomes fixed and cannot be adjusted to adapt to different vehicle mounting spaces
Solution Approach 1:
The busbar component is designed with a flexible bend portion that can be bent to different angles and shapes, transforming the rigid electrical connection structure into a dynamic one. This allows the busbar to adapt to various relative positions between battery cells while maintaining electrical connectivity, directly resolving the contradiction between adaptability and structural complexity
Solution Approach 2:
The busbar component's geometry is changed by bending the flexible portion to different degrees, allowing adjustment of the angle and distance between connection points. This parameter change enables the same busbar structure to accommodate different mounting space requirements without increasing overall system complexity
2Adaptability or versatility
If battery cells are arranged to fit specific vehicle mounting spaces, then adaptability to different vehicles is improved, but production efficiency decreases due to inability to quickly reconfigure
Solution Approach 1:
The flexible bend portion allows the busbar to be quickly reconfigured between different battery cell arrangements without requiring complex repositioning or additional components. This dynamic flexibility enables rapid adaptation to different vehicle mounting space requirements while maintaining high production efficiency
Solution Approach 2:
A single busbar component design with flexible bend portion can serve multiple functions by being bent to different configurations. This universal design allows the same component to adapt to various vehicle types and mounting space requirements, eliminating the need for multiple specialized connection structures and improving production efficiency
3Adaptability or versatility
If the flexible bend portion has greater width than the distance between electrode terminals, then adjustment range is increased, but contact resistance may occur if the flexible portion touches the battery cell end faces
Solution Approach 1:
The busbar component is designed with different local properties: the flexible bend portion has specific width and flexibility characteristics that allow it to achieve the necessary adjustment range while its localized dimensions are controlled to prevent contact with battery cell end faces, thus maintaining both adaptability and electrical conductivity reliability
Data Source
AI summary
This application discloses a battery, an electrical device, and a method and device for manufacturing a battery. The battery includes: a plurality of battery cells arranged along a first direction, where electrode terminals are disposed on two end faces of each of the battery cells along the first direction respectively; and a busbar component, configured to connect the two electrode terminals to implement electrical connection between two battery cells. The busbar component includes a flexible bend portion. The flexible bend portion is configured to adjust a relative position between the two electrode terminals. A maximum width of the flexible bend portion along the first direction is greater than a distance between the two electrode terminals. The flexible bend portion disposed in the busbar component can be bent in various forms to meet a requirement of electrically connecting the two battery cells arranged at a variety of relative positions.