Integrated Monolithic Bus Bar Element for Battery Assembly
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Solution Overview
Problem
The existing battery assembly processes are complex and prone to connection failures due to numerous connection points, leading to high costs and low reliability, particularly because traditional fusing elements require connections at both ends and crimp connections to battery cells, making assembly inconvenient and unreliable.
Innovation Solution
An integrated bus bar element is introduced, where the bus bar and branch bars are made of a single conductor and formed as a monolithic piece, eliminating the need for separate connections and reducing the number of connection points, thus simplifying the assembly process and enhancing reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional separate bus bar and branch bar connections are used, then flexibility in design is maintained, but the number of connection points increases leading to higher cost and lower reliability
Solution Approach 1:
The patent merges the bus bar and branch bars into a single integrated conductor piece, eliminating the need for separate connection points between these components. This consolidation directly reduces the total number of connection points in the battery pack while maintaining electrical connectivity, thereby improving reliability without significantly increasing device complexity.
2Ease of manufacture
If multiple separate connection components are used, then design flexibility is maintained, but assembly convenience deteriorates due to numerous connection steps
Solution Approach 1:
By combining the bus bar and branch bars into one integrated component, the patent eliminates multiple assembly steps required for connecting separate parts. This single-piece design allows for simpler installation and reduces the complexity of the assembly process, directly improving ease of manufacture.
3Reliability
If traditional fusing elements with connection points at both ends are used, then protection function is achieved, but the number of connection points increases causing inconvenience in assembly
Solution Approach 1:
The integrated conductor design incorporates protection functions directly into the single piece structure, eliminating the need for separate fusing elements with multiple connection points. This maintains the protective function while significantly improving assembly convenience by reducing the number of components that need to be installed and connected.
Data Source
AI summary
The present disclosure relates to the technical field of battery, and discloses an integrated bus bar element for a battery, a battery and a vehicle; wherein the integrated bus bar element comprises a bus bar (20, 20a, 20b), and a plurality of branch bars (28a-28j) for electrical connection to battery cells (10, 10a, 10b) respectively, and the bus bar (20, 20a, 20b) and the branch bars (28a-28j) are made of a single conductor and integrally formed as a single piece. The integrated bus bar element of the present disclosure eliminates the connection points between the bus bar and the branch bars, a step of connecting the bus bar and the branch bars is not required to be implemented during the battery assembly, thus the reliability and assembly convenience of the battery are greatly improved.