Flexible Multi-Layer Busbar Structure for Battery Expansion Loads
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Solution Overview
Problem
Existing busbars are thick and costly, requiring manual assembly, leading to high material and production costs, and limiting automated production efficiency.
Innovation Solution
A flexible conductive layer with multiple stacked layers, including bends, connection pieces, and gaps, produced using automated cutting machines, and equipped with sensing and durability layers for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If busbars are made thick to ensure strength and prevent battery expansion force from pulling the conductive layer apart, then strength is improved, but material cost and production cost increase
Solution Approach 1:
The patent uses a composite structure consisting of multiple thin conductive layers (aluminum or copper foil) stacked together with insulation layers in between. This composite structure achieves the required mechanical strength and flexibility while using significantly less material than a single thick busbar, thereby reducing material cost while maintaining strength.
Solution Approach 2:
The conductive layer is divided into multiple thin foils stacked in sequence rather than using one thick piece. Each thin foil is easier to manufacture and assemble, and the stacked structure provides both strength and flexibility. The segmentation allows for automated production processes while reducing overall material consumption.
2Strength
If busbars are made thick to ensure strength, then strength is improved, but production efficiency decreases due to manual assembly requirements
Solution Approach 1:
The conductive layer is divided into multiple thin foils stacked in sequence rather than using one thick piece. Each thin foil is easier to manufacture and assemble, and the stacked structure provides both strength and flexibility. The segmentation allows for automated production processes while reducing overall material consumption.
Solution Approach 2:
The patent uses thin flexible foil structures that can be easily handled and assembled by automated equipment. The thin film nature of each layer allows for flexible routing and automated stacking processes, improving production efficiency compared to manipulating thick rigid busbars.
3Quantity of substance
If multiple thin conductive layers are stacked together to reduce material cost, then material cost is reduced, but structural complexity increases
Solution Approach 1:
The patent uses identical or similar conductive materials (all aluminum or all copper) for each layer, creating a homogeneous structure. The insulation layers are also uniform in composition. This homogeneity simplifies the manufacturing process and assembly procedures despite having multiple layers, as the same processes can be repeated for each layer without requiring different handling procedures.
Solution Approach 2:
The conductive layer is divided into multiple thin foils stacked in sequence rather than using one thick piece. Each thin foil is easier to manufacture and assemble, and the stacked structure provides both strength and flexibility. The segmentation allows for automated production processes while reducing overall material consumption.
4Adaptability or versatility
If bends are formed in conductive layers to create flexibility and alleviate battery expansion force, then flexibility is improved, but manufacturing precision becomes more difficult to achieve
Solution Approach 1:
The conductive layer is divided into multiple thin foils stacked in sequence rather than using one thick piece. Each thin foil is easier to manufacture and assemble, and the stacked structure provides both strength and flexibility. The segmentation allows for automated production processes while reducing overall material consumption.
Solution Approach 2:
The patent uses thin flexible foil structures that can be easily handled and assembled by automated equipment. The thin film nature of each layer allows for flexible routing and automated stacking processes, improving production efficiency compared to manipulating thick rigid busbars.
Data Source
AI summary
A flexible conductive layer is provided with bending parts for alleviating the expansion force of batteries. It includes multiple layers of stacked conductive layers, with bending parts formed inside the conductive layers to form the bending parts, and intervals set between the bending parts of adjacent conductive layers. The structure is simple, and is formed by stacking multiple layers of conductive layers. The conductive layers can be produced using roll materials and fully automatic circular blade/laser cutting machines, and subsequent processes such as attaching insulation layers can be fully automated, saving labor costs and increasing production efficiency.