Integrated Battery Busbar Assembly for Lower Module Height
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Solution Overview
Problem
Current power battery busbar assemblies are heavy, complex, and costly due to their structure, leading to increased weight, height, and manufacturing time, with complex design and environmental pollution concerns.
Innovation Solution
A busbar component with a simplified structure comprising a busbar assembly integrated with insulating layers, eliminating the need for an upper cover and busbar bracket, using mechanical cutting and unloading processes to reduce weight and cost, and incorporating aluminum sampling lines to replace expensive FPC protective films.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a centralized busbar assembly with upper cover and busbar bracket is used, then the FPC and busbar are properly insulated and protected, but the module height increases and weight increases
Solution Approach 1:
The patent integrates the upper cover and busbar bracket into a single integrated component. The upper cover includes an integrated busbar bracket portion that directly supports the busbar, eliminating the need for a separate bracket component. This merging reduces the number of parts and simplifies the overall structure while maintaining the insulation and support functions.
Solution Approach 2:
The patent removes the separate busbar bracket component from the traditional assembly. By integrating the bracket function into the upper cover structure itself, the design eliminates unnecessary components and reduces module height while preserving the structural support and insulation functions.
2Reliability
If a centralized busbar assembly with upper cover and busbar bracket is used, then the FPC and busbar are properly insulated and protected, but the weight of the module increases
Solution Approach 1:
The patent combines the upper cover and busbar bracket into one integrated component, reducing the total material used and eliminating redundant structural elements. This merging reduces the overall weight while maintaining the necessary insulation and support functions.
Solution Approach 2:
By removing the separate busbar bracket component and integrating its function into the upper cover, the patent reduces the total weight of the busbar assembly while preserving the structural support and insulation capabilities.
3Device complexity
If a busbar bracket is designed and manufactured separately, then the busbar assembly can be properly structured, but the processing period increases and manufacturing complexity increases
Solution Approach 1:
The patent integrates the busbar bracket function into the upper cover structure, allowing both components to be manufactured as a single piece or pre-assembled unit. This eliminates the need for separate manufacturing and assembly steps, reducing processing time and complexity while maintaining structural integrity.
4Reliability
If traditional FPC protective film is used, then the sampling line is protected, but the cost increases and environmental pollution occurs
Solution Approach 1:
The patent removes the separate FPC protective film component and replaces it with the integrated upper cover structure that provides protection for the sampling line. This eliminates the need for additional protective films and their associated costs and environmental issues.
Data Source
AI summary
Disclosed are a power battery, a busbar component of the power battery and a method thereof. The busbar component comprises a busbar assembly. The busbar assembly comprises a busbar body, a first insulating layer and a second insulating layer. The busbar body is connected with one side of the first insulating layer facing a battery cell module, is integrated with a sampling line, and the sampling line is manufactured by a mechanical cutting and unloading process. The second insulating layer is attached to the first insulating layer and covers the sampling line, and the second insulating layer and the busbar body are on a same side of the first insulating layer and are arranged in a staggered manner. The cost is lowered, the process cycle of product is shortened, the production efficiency is improved, the applicability gets wider, the production process and the assembling process are simplified.