Irregular Battery Cell Connection via Segmented Busbar
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Solution Overview
Problem
Existing battery connection technologies are inadequate for connecting a large number of battery cells irregularly arranged, as they are designed for symmetric and regular configurations, limiting their ability to connect cells that are not positioned symmetrically.
Innovation Solution
A battery connection module comprising a tray with multiple connecting busbars, each with components that connect battery cells across adjacent columns, rows, and columns, allowing for the connection of more battery cells with irregular arrangements by using a single busbar to span multiple cells and utilizing different configurations for each busbar to accommodate staggered cell positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a symmetric and regular arrangement of tab-shaped connecting points is used on conductive plates, then the connection structure is simple and regular, but it cannot connect more than two adjacent rows of batteries (e.g., cannot connect ten batteries when only six are positioned symmetrically)
Solution Approach 1:
The conductive plate is divided into multiple segments or zones with different connecting point arrangements. Each segment can have its own pattern of connecting points, allowing the plate to connect to varying numbers of battery rows (e.g., 6 rows in one segment, 10 rows in another). This segmentation enables the single conductive plate to adapt to different battery configurations without requiring a completely different plate design for each case.
Solution Approach 2:
The patent introduces asymmetric arrangements of tab-shaped connecting points on the conductive plate. Instead of requiring all connecting points to be symmetrically positioned, the plate can have connecting points distributed asymmetrically to match irregular battery placements. This allows the conductive plate to connect to an odd number of battery rows or non-uniform configurations that cannot be accommodated by symmetric patterns alone.
2Adaptability or versatility
If conductive plates with symmetric tab-shaped connecting points are used, then manufacturing is easy and standardized, but the connecting points must be positioned at regular intervals which limits flexibility
Solution Approach 1:
The conductive plate is designed as a universal component that can serve multiple functions by incorporating various types of connecting points in different arrangements. A single conductive plate design can connect to 6-row configurations, 10-row configurations, or intermediate arrangements by selectively engaging different sets of tab-shaped connecting points. This multi-functionality reduces the need for multiple specialized plate designs while maintaining manufacturing efficiency.
Solution Approach 2:
The connecting points on the conductive plate are designed with dynamic positioning capabilities, allowing their effective arrangement to change based on the battery configuration. This can be achieved through movable connecting elements or selectable engagement points that can be activated or deactivated depending on whether the battery arrangement requires 6-row or 10-row connectivity, providing adaptability without sacrificing manufacturing simplicity.
Data Source
AI summary
A battery connection module and a battery pack are provided. The battery connection module includes a plurality of connecting busbars which are assembled on a tray. Each connecting busbar has a plurality of components, each component has a main body portion, a head portion which extends from a first end of the main body portion and a foot portion which extends from a second end of the main body portion, the head portion is connected to a positive electrode of a corresponding battery cell, the foot portion is connected to a negative electrode of a corresponding battery cell, the main body portions of the components of the connecting busbar are connected by a connecting portion. In each connecting busbar, at least one component connects two battery cells of adjacent columns, at least one component connects two battery cells of every other column, at least one component connects two battery cells in the same row, and at least one component connects two battery cells of adjacent rows.