Integrated Shunt Busbar for Battery Systems
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery systems require additional dedicated shunts and circuit carriers, increasing costs and installation space, while also facing challenges in managing dynamic power demands and preventing overheating.
Innovation Solution
A busbar with integrated shunt resistance, made from materials like manganin or constantan, which connects battery cells and terminals, reducing the need for additional shunts and circuit carriers, and allowing for efficient heat management and voltage balancing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If additional dedicated shunts and circuit carriers are used to measure current and manage power, then measurement precision and power management capability are improved, but device complexity and installation space increase
Solution Approach 1:
The patent combines the shunt resistance and circuit carrier functions into the busbar structure itself. The busbar includes integrated shunt resistance that serves both as current measurement element and as part of the electrical connection structure, eliminating the need for separate dedicated shunts and circuit carriers. This merging reduces device complexity while maintaining measurement precision.
Solution Approach 2:
The busbar is designed to perform multiple functions simultaneously: it serves as an electrical connector, contains integrated shunt resistance for current measurement, and provides thermal management pathways. This multi-functionality eliminates the need for separate dedicated components, reducing both device complexity and installation space while maintaining measurement capabilities.
2Productivity
If additional dedicated shunts and circuit carriers are installed, then current measurement and power management capabilities are improved, but material costs and installation space increase
Solution Approach 1:
The shunt resistance and circuit carrier functions are merged into the busbar structure, eliminating the need for separate dedicated components. This reduces the quantity of materials required and decreases installation space while maintaining power management efficiency.
Solution Approach 2:
The busbar serves multiple functions including electrical connection, current measurement through integrated shunt resistance, and thermal management. This multi-functionality reduces the overall material quantity needed compared to using separate dedicated components for each function.
3Reliability
If separate shunts and circuit carriers are used, then measurement and control functions are improved, but manufacturing complexity and assembly steps increase
Solution Approach 1:
The shunt resistance and circuit carrier are merged into the busbar as an integrated structure, reducing the number of assembly steps. The busbar can be manufactured as a single component with embedded shunt resistance, eliminating the need to assemble separate shunt and circuit carrier components, thereby improving ease of manufacture while maintaining measurement reliability.
4Temperature
If more components are added for thermal management, then heat dissipation capability is improved, but device complexity and installation space increase
Solution Approach 1:
The busbar serves dual functions as both an electrical connector and a thermal management component. The integrated shunt resistance and busbar structure provide thermal pathways for heat dissipation without requiring separate dedicated thermal management components, thereby improving heat dissipation capability while avoiding increased device complexity.
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 integrated shunt busbar reduces material costs and installation space, improves electrical connectivity, and enhances thermal management, enabling more efficient battery system operation and extended lifespan.
Implementation Method 1
the third member, which electrically connects the first bar member and the second bar member, is formed as the shunt resistance
Implementation Method 2
A busbar with integrated shunt resistance, made from materials like manganin or constantan, which connects battery cells and terminals, reducing the need for additional shunts and circuit carriers, and allowing for efficient heat management
Data Source
AI summary
A busbar for a battery system according to an exemplary embodiment of the present invention includes: a first bar member and a second bar member which are spaced apart from each other; and a third bar member which connects the first bar member and the second bar member to define a common bar, in which the third bar member is shunt resistance having ohmic resistance and electrically connects the first bar member and the second bar member. In addition, a battery system according to the exemplary embodiment of the present invention includes the busbar.