Folded Busbar Integrating Voltage Detection Terminals
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Solution Overview
Problem
The existing methods for connecting multiple battery terminals and integrating voltage detection terminals with printed circuits in electric vehicles or hybrid cars are cumbersome, requiring separate processes for welding, soldering, and pressure welding, leading to low productivity and difficulty in maintaining consistent contact between electrode posts of varying heights.
Innovation Solution
A busbar made from a folded rectangular conductive metal plate with integrated voltage detection terminals, featuring hinge portions and a locking protrusion, allows for flexible assembly and secure contact without the need for additional welding processes, ensuring consistent contact even with height variations between electrode posts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate welding and soldering processes are used to connect battery terminals and voltage detection terminals, then reliable electrical connection is achieved, but productivity decreases and manufacturing complexity increases
Solution Approach 1:
The voltage detection terminal and battery terminal are integrated into a single busbar component, merging two previously separate connection functions into one element. This eliminates the need for separate welding and soldering processes, as the integrated design allows both battery connection and voltage detection terminal connection to be achieved through a single assembly operation, thereby improving productivity while maintaining reliable electrical connections.
2Reliability
If multiple separate connection processes are used for battery terminals and voltage detection terminals, then secure connections are achieved, but manufacturing complexity increases
Solution Approach 1:
The invention combines the battery terminal connection function and voltage detection terminal connection function into a single integrated busbar structure. This merging reduces manufacturing process complexity by eliminating multiple separate connection steps (welding, soldering, pressure welding) and replacing them with a single assembly process where the integrated busbar is installed, securing both connections simultaneously.
Solution Approach 2:
The busbar is designed as a multi-functional component that simultaneously serves as the battery terminal connector and the voltage detection terminal support. This universal design allows one component to perform multiple functions that previously required separate components and processes, thereby simplifying the manufacturing process while ensuring secure connections for both battery terminals and voltage detection terminals.
3Stability of the object's composition
If rigid connection structures are used for battery terminals, then structural stability is achieved, but adaptability to height variations decreases
Solution Approach 1:
The busbar incorporates a flexible portion that allows dynamic adjustment to accommodate height variations between battery electrode posts. This flexible section enables the rigid portions of the busbar to adapt their position and orientation, maintaining stable electrical connections despite variations in electrode post heights, thereby combining structural stability with adaptability.
Data Source
Figure 1A~1C
Figure 2A~2B
Figure 3
AI summary
A busbar for battery electrode post connection capable of omitting a process of welding, solder, pressure welding, etc. for connecting a terminal for voltage detection to the busbar and surely making contact between electrode posts and the busbar even when the electrode posts of a battery and an adjacent battery vary in height is provided. Both ends (hinge parts) 10H, 10H of a length direction of a rectangular thin plate of a conductive metal are left and an elongated opening 10K is formed in a center and two holes 10L, 10L through which an electrode post of one battery and an electrode post of an adjacent battery extend are respectively bored in the rectangular thin plates 11, 12 of both sides around the elongated opening 10K of the center and a terminal 13 for voltage detection is extended integrally to the rectangular thin plate 12 from an edge of the rectangular thin plate 12. Consequently, the two holes 10L, 10L overlap respectively in a state of folding the rectangular thin plates 11, 12 of both sides in two around the elongated opening 10K of the center and the terminal 13 for voltage detection is erected from the rectangular thin plate 12 by folding the terminal 13 for voltage detection in a vertical direction.