Layered Battery Busbar for Uniform Cell Current Distribution
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Solution Overview
Problem
Existing battery technologies face challenges in achieving uniform current distribution and minimizing power loss across individual cells, necessitating improved electrical connections.
Innovation Solution
A busbar design with multiple conductor layers, each insulated from each other except at specific contact points, ensures equal current paths and homogeneous current distribution by strategically placing contact points to manage current flow direction and resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional single-layer busbar designs are used, then the structure is simple, but homogeneous current distribution across battery cells cannot be achieved
Solution Approach 1:
The busbar is divided into multiple conductor layers (at least two layers) stacked one above the other, with each layer serving specific current distribution functions. The conductor layers are electrically insulated from each other except at specific contact points, creating segmented current paths that ensure homogeneous current distribution across all battery cells.
Solution Approach 2:
The invention transitions from a single-plane (2D) busbar design to a multi-layer stacked structure (3D), adding the vertical dimension through stacked conductor layers. This dimensional change allows current to distribute more uniformly across the battery cell array by providing multiple parallel current paths at different vertical levels.
2Strength
If conductor layers are stacked to achieve mechanical stability, then structural strength improves, but electrical insulation between layers must be maintained
Solution Approach 1:
An insulating layer is introduced as an intermediary between the stacked conductor layers. This insulating layer prevents electrical short circuits between layers while allowing the conductor layers to be mechanically stacked for structural stability. The insulation is applied selectively, allowing electrical contact only at designated contact points.
3Loss of energy
If contact points are strategically placed to equalize current paths, then power loss is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The busbar design implements local quality by providing electrical insulation between conductor layers at most locations, while creating specific localized contact points where electrical connection is required. These contact points are strategically positioned to equalize current path lengths and reduce power loss, with the insulating layer applied selectively rather than uniformly.
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 busbar design achieves uniform current distribution and reduces power loss by ensuring equal electrical resistance in current paths, facilitating efficient charging and discharging of battery cells.
Implementation Method 1
The conductor layers are electrically insulated from each other except at specific contact points. This insulation can be achieved, for example, by a varnish or a non-conductive layer.
Implementation Method 2
The at least two conductor layers stacked one above the other are electrically connected to each other at the contact points via at least one welding spot.
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
The invention relates to a busbar (10) for an electric battery (20) for electrically connecting a plurality of individual cells (21) of the battery (20), said busbar comprising at least two conductor layers (Lu, Lo) stacked one on top of the other. The conductor layers (Lu, Lo) are electrically insulated from one another except at specified contact points (P1, P2). A bottom conductor layer (Lu) has, at a first end, a main connection (T) for connection of a power supply. A top conductor layer (Lo) is electrically connected to the bottom conductor layer (Lu) via at least a first contact point (P1) and a second contact point (P2). The electrical resistance along a first current path between the main connection (T) and the first contact point (P1) is equal to the electrical resistance along a second current path between the main connection (T) and the second contact point (P2).