Laminated Busbar Layout for Faster Battery Cell Interconnection
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Solution Overview
Problem
Conventional busbars for interconnecting cylindrical battery cells are time-consuming and costly to produce, with existing solutions like laminated and printed conductive layers requiring complex configurations and quality control challenges.
Innovation Solution
A laminated busbar design featuring a conductive band on an insulating layer with pre-stamped metal coils, optimized for welding and allowing access to terminators through openings, reducing thickness and manufacturing complexity while enabling easy modification for various applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional laminated busbar or printed conductive layer is used, then electrical connection is achieved, but manufacturing time and cost increase
Solution Approach 1:
The busbar is divided into modular units with standardized connection interfaces. Each module contains pre-defined conductor patterns and terminators that can be independently manufactured and then assembled, reducing overall manufacturing complexity and time while maintaining connection reliability
Solution Approach 2:
Conductor patterns are pre-stamped into metal coils before final assembly. This preliminary formation of conductive paths eliminates time-consuming on-site wiring and connection processes, significantly improving manufacturing efficiency while ensuring consistent connection quality
2Reliability
If complex laminated structure with multiple layers is used, then connection reliability improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The insulator is extracted as a separate, simplified component rather than being integrated into a complex multi-layer laminate. This allows the conductive elements to be arranged in a single plane with straightforward connections, reducing structural complexity while maintaining electrical isolation and connection reliability
Solution Approach 2:
The busbar design incorporates universal connection interfaces and standardized terminator configurations that can be used across different module types and applications. This multi-functionality reduces the need for custom-designed complex structures, simplifying manufacturing while ensuring reliable connections
3Reliability
If traditional wire connection method is used, then electrical connection is achieved, but quality control difficulty and cost increase
Solution Approach 1:
Traditional mechanical wire connections and manual soldering are replaced with precision stamping and crimping processes. These standardized mechanical connection methods provide consistent, measurable connection parameters that are easier to detect and control quality-wise, reducing both cost and difficulty while maintaining high connection quality
Data Source
AI summary
A laminated busbar for interconnecting electrical storage devices, comprising an insulating layer and at least one conductive band arranged on the insulating layer, the at least one conductive band comprising a succession of repeating conductor patterns, each conductor pattern defining a cluster having a first terminal and a second terminal for connection to an energy storage device. The laminated busbar also comprises a first terminator coupled to the first terminal and a second terminator coupled to the second terminal, the first and second terminators configured to connect to terminals of the energy storage device.