Layered Flexible Busbar Assembly for Battery Expansion Loads
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Solution Overview
Problem
Existing busbars are thick and costly, requiring manual assembly, limiting production efficiency and safety, and are prone to breakage due to battery expansion forces.
Innovation Solution
A flexible conductive busbar with fuses, comprising multiple stacked layers of conductive busbars and connection layers, produced using automatic cutting machines, with fuses that ensure conductivity and safety by melting under high currents, and absorb battery expansion forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If busbar thickness is increased to ensure strength and prevent breakage from battery expansion force, then reliability is improved, but material cost and production cost increase
Solution Approach 1:
The patent uses a composite structure consisting of multiple thin conductive busbar layers stacked together with conductive connection layers between them. This composite approach provides the necessary mechanical strength and reliability to resist battery expansion forces while using less material than a single thick busbar, thereby reducing material cost.
Solution Approach 2:
The busbar is segmented into multiple thin layers that are stacked and connected. This segmentation allows the structure to maintain flexibility and strength while reducing the amount of material needed compared to a single solid thick busbar, resolving the contradiction between reliability and material cost.
2Manufacturing precision
If busbars are formed by one-time stamping and manually assembled, then manufacturing precision is maintained, but productivity decreases and labor costs increase
Solution Approach 1:
The conductive busbars and conductive connection layers are prepared as separate components in advance, allowing for automated assembly. This preliminary preparation enables the use of automated stacking and connection processes, improving productivity while maintaining manufacturing precision through controlled assembly procedures.
Solution Approach 2:
The patent replaces manual assembly operations with automated stacking and connection processes. The conductive busbars and connection layers can be automatically stacked and bonded using automated equipment, eliminating manual labor and significantly improving production efficiency while maintaining consistent quality.
3Ease of manufacture
If manual assembly is used for producing CCS, then ease of manufacture is maintained, but productivity decreases and labor costs increase
Solution Approach 1:
The conductive busbars and conductive connection layers are pre-prepared as standardized components, enabling automated assembly processes. This preliminary standardization maintains ease of manufacture through modular components while dramatically improving productivity through automation.
Solution Approach 2:
The stacked conductive busbar structure with integrated fuses creates a universal component that can be automatically assembled into different CCS configurations. This multi-functional design allows automated production lines to produce various battery connections using the same basic component structure, improving both ease of manufacture and productivity.
4Reliability
If thick busbars are used to ensure strength, then reliability is improved, but adaptability decreases due to limited flexibility
Solution Approach 1:
The composite structure of multiple thin conductive busbar layers with conductive connection layers provides both the necessary mechanical strength and the flexibility needed for adaptability. The layered construction allows the busbar to bend and conform to different configurations while maintaining structural integrity and electrical conductivity.
Solution Approach 2:
Segmenting the busbar into multiple thin layers that are stacked and connected provides both strength through the layered structure and flexibility through the ability of the layers to move relative to each other. This segmentation enables the busbar to adapt to different battery configurations and mounting requirements while maintaining reliability.
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
Enhances production efficiency, reduces labor costs, improves safety, and extends lifespan by automating assembly and mitigating battery expansion impacts.
Implementation Method 1
the fuses are not only used for electrical connection between connection bars to ensure the conductivity of the flexible conductive busbar but also fuse timely when subjected to abnormally high currents
Implementation Method 2
the fuses can mitigate vibrations and absorb stretching caused by battery expansion, enhancing the stability and lifespan of the flexible conductive busbar
Data Source
AI summary
A flexible conductive busbar with a fuse, comprising several layers of stacked conductive buses and conductive connection layers set between adjacent conductive buses. The conductive bus includes two spaced connection buses and a fuse connected between the two connection buses. The conductive connection layer includes two connection pieces respectively set between the corresponding connection buses.