Folded Busbar Uniform Current Distribution
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Solution Overview
Problem
Conventional busbars with a two-layer structure experience current deviation and increased electrical resistance due to oxide films and uneven current paths, leading to poor connection reliability and high resistance.
Innovation Solution
A busbar design with a central region and parallel end regions folded on top, creating a gap for uniform current flow and exposed connection areas for reliable laser welding and positioning, reducing electrical resistance and enhancing connection reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the plate thickness of the busbar is increased to reduce electrical resistance, then the electrical resistance decreases, but the size of the wire connection portion increases
Solution Approach 1:
The busbar is divided into a body portion and a wire connection portion with different thickness characteristics. The body portion has increased thickness (achieved through folding) to reduce electrical resistance, while the wire connection portion maintains conventional thickness to keep size manageable. This segmentation allows each part to be optimized independently for its specific function.
Solution Approach 2:
Different regions of the busbar are given different thickness properties: the body portion spanning adjacent electrode terminals has increased thickness for low electrical resistance, while the wire connection portion extending from the body portion maintains conventional thickness. This local differentiation of quality (thickness) optimizes each region for its specific functional requirements.
2Loss of energy
If a single metal plate is folded to create a two-layer structure, then the thickness of the body portion is increased, but current deviation occurs due to oxide films and uneven current paths
Solution Approach 1:
A groove is introduced as an intermediary feature between the two folded layers of the busbar. This groove removes oxide films and prevents direct contact between the folded layers, eliminating the source of current deviation. The groove acts as a mediator that ensures uniform current distribution across the busbar thickness without being blocked by oxide films.
Solution Approach 2:
The problematic oxide films and uneven current paths are removed by introducing grooves between the folded layers. This extraction of the harmful elements (oxide films) from the interface between layers eliminates the cause of current deviation and improves connection reliability.
3Loss of energy
If the busbar is formed with a two-layer stacked structure, then the body portion thickness is increased, but manufacturing complexity increases due to folding and alignment requirements
Solution Approach 1:
The busbar is designed with pre-formed grooves that guide the folding process and ensure proper alignment of the layers. These preliminary structural features are built into the design to facilitate easier manufacturing and assembly, reducing the complexity that would otherwise result from precise folding and alignment requirements.
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
The busbar design ensures uniform current distribution, reduces electrical resistance, and improves connection reliability by allowing easy adjustment of laser welding and secure positioning of electrode terminals, resulting in a more efficient energy transfer.
Implementation Method 1
a busbar that establishes a connection between adjacent electrode terminals of a plurality of electricity storage elements... a current flowing out from the positive electrode to the negative electrode side... uniform current distribution... reduces electrical resistance
Implementation Method 2
allowing easy adjustment of laser welding... secure positioning of electrode terminals
Data Source
AI summary
Provided is a busbar configured to establish a connection between adjacent electrode terminals of a plurality of electricity storage elements each including positive and negative electrode terminals, including: a central region and a pair of end regions that are separated by a pair of parallel folding lines extending along an arrangement direction of the adjacent electrode terminals, wherein the pair of end regions are folded using the folding lines, and are placed on top of one surface of the central region such that the end regions do not overlap with each other.