Integrated Busbar Battery Cell Terminal Design
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Solution Overview
Problem
Existing battery pack assemblies face issues with high electrical resistance and manufacturing complexity due to numerous separate busbar connections, which lead to potential undesirable performance and increased mass.
Innovation Solution
Integration of a busbar within the battery cell terminals allows for direct electrical communication between adjacent cells, reducing the number of components and interfaces, thereby minimizing electrical resistance and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate busbars with multiple electrical interfaces are used to interconnect battery cells, then electrical connections can be established between cells, but electrical resistance increases and manufacturing complexity increases
Solution Approach 1:
The patent merges the busbar function directly into the terminal structure by integrating a conductive element within the terminal housing. This eliminates separate busbar components and their associated electrical interfaces, thereby reducing electrical resistance while maintaining reliable electrical connections between battery cells.
2Reliability
If separate busbars with multiple electrical interfaces are used to interconnect battery cells, then electrical connections can be established between cells, but manufacturing complexity increases
Solution Approach 1:
The terminal and busbar functions are combined into a single integrated component. The terminal housing incorporates a conductive element that serves as the busbar, eliminating the need for separate busbar components and multiple assembly steps, thereby significantly reducing manufacturing complexity.
Solution Approach 2:
The terminal structure is designed to perform multiple functions: it provides electrical connection points for the battery cell and simultaneously serves as the busbar for intercell electrical connections. This multi-functional design reduces the total number of components and simplifies the overall assembly process.
3Reliability
If separate busbars with multiple electrical interfaces are used to interconnect battery cells, then electrical connections can be established between cells, but mass increases
Solution Approach 1:
By integrating the conductive element within the terminal housing, the patent eliminates the need for separate busbar components. This consolidation reduces the total mass of electrical connection components while maintaining reliable electrical connections between battery cells.
4Ease of manufacture
If multiple electrical interfaces along the busbar are used to connect battery cells, then electrical connections can be established, but the likelihood of undesirable battery pack performance increases
Solution Approach 1:
The integration of the conductive element within the terminal housing reduces the number of electrical interfaces along the connection path. Fewer interfaces mean fewer potential failure points, thereby reducing the likelihood of undesirable battery pack performance while maintaining ease of assembly.
Data Source
AI summary
A battery cell has a main body including active material configured to generate power from an electrochemical reaction. A first terminal is disposed on the main body and includes an integrated busbar. The integrated busbar is configured to place the battery cell in electrical communication with a second terminal of an adjacent battery cell.