Laminated Busbars for Battery Modules
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Solution Overview
Problem
Existing busbar technologies, particularly bent busbars, face challenges such as high cost, complex assembly, and vulnerability to mechanical stresses, which can lead to insecure connections and potential short circuits in large battery systems, compromising safety and efficiency.
Innovation Solution
The introduction of laminated busbars with a heat-resistant dielectric sheet supporting conductive foil, incorporating fusible links and flexible joints, which integrates voltage and temperature sensing capabilities, reduces assembly complexity and enhances mechanical resilience by allowing secure connections without the need for wire bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bent busbars are used to connect battery cells, then electrical connection is achieved, but the assembly complexity increases and manufacturing cost rises
Solution Approach 1:
The busbar is divided into multiple rigid segments that are individually connected to battery cell terminals, with flexible joints between segments. This segmentation allows each segment to be independently positioned and secured, simplifying the overall assembly process while maintaining reliable electrical connections throughout the battery pack.
Solution Approach 2:
A flexible joint acts as an intermediary element between rigid busbar segments, enabling mechanical connection without requiring complex bending operations. This intermediary component simplifies manufacturing by allowing standard rigid segments to be connected through a dedicated flexible element rather than requiring the entire busbar to be bent into complex shapes.
2Reliability
If bent busbars are used to connect battery cells, then electrical connection is achieved, but manufacturing cost increases
Solution Approach 1:
The busbar system is segmented into standardized rigid sections that can be manufactured using simple cutting and forming processes, avoiding the need for expensive complex bending operations. Each segment is a discrete component that can be efficiently produced and then assembled using the flexible joint connectors.
Solution Approach 2:
The design transitions from a continuous bent busbar to discrete rigid segments connected by flexible joints, changing the physical parameters of the connection system. This parameter change allows for simpler manufacturing processes while maintaining the necessary electrical and mechanical functionality.
3Reliability
If traditional busbars are used, then electrical conduction is provided, but vulnerability to mechanical stresses increases
Solution Approach 1:
The flexible joint introduces dynamic capability to the busbar system, allowing it to adapt to mechanical stresses through controlled movement and deformation. This dynamic element absorbs vibration and thermal expansion forces that would otherwise be transmitted through the entire busbar structure, protecting rigid segments and electrical connections from damage.
Solution Approach 2:
The flexible joint acts as a pre-designed cushioning element that anticipates and absorbs mechanical stresses before they can damage the electrical connections. By incorporating this compliant element in advance, the system is protected from vibration and thermal stress without requiring additional protective measures during operation.
4Reliability
If secure connections are made to withstand vibration and thermal expansion, then connection reliability improves, but assembly complexity increases
Solution Approach 1:
The busbar is segmented into rigid sections that are individually secured to battery cell terminals, with each segment providing a focused, reliable connection point. This segmentation allows for simpler attachment methods at each location rather than requiring a single complex securement system for the entire busbar.
Solution Approach 2:
The flexible joint serves as an intermediary that provides mechanical compliance while maintaining electrical continuity. This intermediary element handles the accommodation of thermal expansion and vibration, allowing rigid segments to be securely attached to terminals without requiring the entire busbar system to be overly complex or rigid.
Data Source
AI summary
A laminated busbar assembly includes positive and negative leads supported by an insulative layer. The insulative layer as well as the positive and negative leads are thin and flexible, thus facilitating connection of the positive and negative leads with the terminals of the electric cells of a battery module. The laminated busbar assembly may include voltage measurement wires and/or temperature sensors for measuring voltage and/or temperature, respectively.