Layered Battery Busbar Layout for Uniform Cell Current
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Solution Overview
Problem
Existing battery technologies face challenges in achieving uniform current distribution across individual cells, leading to inefficiencies in power dissipation and strain, while maintaining mechanical stability and ease of manufacturing.
Innovation Solution
A busbar design comprising multiple conductor layers, each insulated except at specific contact points, with carefully arranged current paths to ensure equal resistance and distribution, achieved through methods like welding or folding, allowing for homogeneous current flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If multiple conductor layers are stacked to achieve mechanical stability and ease of manufacturing, then structural integrity is improved, but current distribution uniformity may deteriorate due to unequal current paths
Solution Approach 1:
The patent transitions from a single-plane conductor to a multi-layer stacked structure, adding the vertical dimension to current distribution. Multiple conductor layers are stacked with insulating layers between them, creating three-dimensional current paths that can be designed to achieve uniform current distribution while maintaining mechanical stability.
Solution Approach 2:
The patent applies different properties to different parts of the conductor structure. Insulating layers are selectively placed between conductor layers at specific locations, and contact points are positioned at specific coordinates (e.g., first contact point in first third, second contact point in third third) to create localized current distribution patterns that achieve overall uniformity.
2Manufacturing precision
If contact points are positioned to achieve homogeneous current distribution, then current uniformity is improved, but power dissipation increases due to longer current paths
Solution Approach 1:
The patent divides the current path into multiple parallel segments through the stacked conductor layers. By creating multiple contact points (first contact point and second contact point) at different positions along the conductor, the current is segmented into parallel paths that can be optimized to reduce total path length while maintaining uniform distribution.
Solution Approach 2:
The patent uses the vertical stacking dimension to create parallel current paths that are electrically equivalent but spatially separated. This allows current to be distributed across multiple layers simultaneously, reducing the effective path length in any single layer while maintaining overall current uniformity across all cells.
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 ensures uniform current distribution across cells, reducing power dissipation and mechanical stress, while being cost-effective and easy to manufacture.
Implementation Method 1
The conductor layers are electrically insulated from each other except at specific contact points. The insulation may for instance be achieved through paint or through a non-conducting layer.
Implementation Method 2
The electrical connection may for instance be achieved by welding or folding together the conductor layers.
Data Source
AI summary
A busbar (10) for an electric battery (20) for electrically connecting a plurality of individual cells (21) of the battery (20) comprises at least two conductor layers (Lu, Lo) stacked one on top of the other. The conductor layers (Lu, Lo) are electrically insulated from each other except at specific contact points (P1. P2). A bottom conductor layer (Lu) comprises, at a first end, a main terminal (T) for connecting 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 terminal (T) and the first contact point (P1) is the same as the electrical resistance along a second current path between the main terminal (T) and the second contact point (P2).