Mesh Contact Element for Thermal Stress in Energy Storage

The patent applies a flexible busbar design that can bend and deform to accommodate thermal expansion and contraction of electrical components. The flexible busbar includes a substrate layer with conductive layers that maintain electrical contact while flexing, allowing the connection to absorb mechanical stress from temperature variations without failing. This resolves the contradiction by providing both electrical conductivity and thermal stress resistance through flexibility.

The patent changes the physical parameters of the busbar by using multiple conductive layers with different properties (copper layer for conductivity, aluminum layer for thermal management, silver layer for contact resistance reduction). The layered structure allows each layer to respond differently to thermal stress while maintaining overall electrical connection stability, resolving the contradiction between conductivity and thermal resistance.

The mesh contact element is formed from a flexible substrate with conductive patterns that can deform under thermal stress. The mesh structure provides mechanical compliance to absorb expansion and contraction forces while the continuous conductive paths maintain electrical contact. This resolves the contradiction by demonstrating that flexibility does not necessarily reduce electrical contact reliability when properly designed.

The contact element uses composite construction with multiple conductive layers (copper, aluminum, silver) deposited on a flexible substrate. This composite structure provides both the mechanical flexibility needed for thermal stress resistance and the electrical conductivity required for reliable contact, resolving the apparent contradiction between mesh structure and contact area.

The busbar employs a flexible substrate design that allows controlled deformation to accommodate thermal expansion of connected components. The flexibility is engineered through the substrate material and layer structure, providing adaptability while maintaining sufficient structural integrity through the multi-layer composite construction and anchoring mechanisms.

The busbar is divided into multiple functional layers (substrate, copper layer, aluminum layer, silver layer) that can respond independently to thermal stress. This segmentation allows the structure to flex and adapt to temperature changes while each layer contributes to overall structural strength, resolving the contradiction between flexibility and rigidity.