Laminated Busbar Layout for Faster Prismatic Cell Module Assembly
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Solution Overview
Problem
Conventional busbars for interconnecting prismatic electrical cells are costly and time-consuming to produce due to the need for separate return circuits, which complicates the assembly of battery packs.
Innovation Solution
A laminated busbar with a first conductive layer and a second conductive layer, separated by an insulating layer, allows for efficient connection of cells in series and parallel, with connectors optimized for rapid assembly and reduced material usage, enabling a single busbar to connect multiple modules efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional busbars use separate return circuits, then electrical connection is achieved, but production cost and assembly time increase
Solution Approach 1:
The patent combines the return circuit into the same busbar structure as the forward circuit, merging two previously separate functions into a single integrated component. The busbar now contains both outgoing and return conductive paths within one piece, eliminating the need for separate return circuit assemblies and reducing overall system complexity.
Solution Approach 2:
The busbar is designed to perform multiple functions simultaneously: it provides both the forward circuit connection and the return circuit connection, serves as a structural support element, and enables modular assembly. This multi-functional design reduces the number of separate components needed and simplifies the overall assembly process.
2Reliability
If multiple busbars are used to connect modules, then electrical connection is achieved, but cost and assembly time increase
Solution Approach 1:
The patent integrates both the forward and return circuit paths into a single busbar component, allowing one busbar to perform the work of multiple separate busbars. This reduces the number of assembly operations required and maintains reliable electrical connections for both circuit directions.
Solution Approach 2:
The busbar is designed with distinct segmented regions for the forward circuit and return circuit, allowing each function to be clearly defined while remaining part of a single integrated component. This segmentation within unity enables reliable electrical connections without requiring multiple separate busbars.
3Loss of substance
If laminated structure is used, then material usage is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent employs a laminated structure combining conductive and insulating materials in alternating layers. This composite construction uses materials efficiently by placing conductive layers only where electrical conduction is needed and insulating layers where electrical isolation is required, reducing overall material usage while maintaining manufacturing feasibility through standardized lamination processes.
Data Source
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AI summary
Laminated busbar (100) for interconnecting a pack (20) of prismatic electrical cells (22) in a module (10) from an electrical battery. The cells are configured to be arranged in groups (30) having each the same number of cells. The busbar comprises: - a first electrically conductive layer (110), with at least one electrically conducting element (112), each configured to connect electric poles (28) of two adjacent groups of cells, - a first electrically insulating layer (130), laminated on the first conductive layer, - a first electrical connector (114), configured to be connected to a first group (30A) of cells. Advantageously, the laminated busbar comprises a second electrically conductive layer (140), which is laminated onto the first insulating layer and comprises a second electrical connector (142), configured to be connected to a last group (30B) of cells, and a third electrical connector (144), which is closer to the first electrical connector than to the second electrical connector. The first insulating layer comprises a cut-out window (134), configured to allow the electrical connection of the second electrical connector with the last group of cells.