Multi-Material Bus Bar Link for Low-Resistance Battery Module Assembly
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Solution Overview
Problem
Existing battery systems face challenges in efficiently coupling battery cells with different terminal materials, leading to increased electrical resistance, bulkiness, and improper placement or misalignment of bus bars, which complicates assembly and reduces performance.
Innovation Solution
A bus bar system with collars made of different materials to securely surround and couple battery terminals, along with a joint providing a gas-tight seal and mechanical connection, simplifying installation and reducing electrical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional single-material bus bars are used to connect battery terminals of different materials, then manufacturing is simpler, but electrical resistance increases and connection reliability deteriorates
Solution Approach 1:
The bus bar is designed with different materials at different locations: the first end is made of aluminum to match aluminum battery terminals, while the second end is made of copper to match copper battery terminals. This local differentiation of material properties optimizes electrical conductivity and connection reliability at each interface, resolving the contradiction between connection reliability and manufacturing simplicity.
2Ease of operation
If bus bars without collars are used, then the structure is simpler, but misalignment and improper placement occur reducing assembly ease
Solution Approach 1:
Collars are added to the bus bar that protrude from the body and are configured to receive and surround the battery terminals. These collars perform the preliminary action of guiding and positioning the terminals before the final connection is made, preventing misalignment and improper placement during assembly, thus improving assembly ease while accepting increased structural complexity.
3Reliability
If material-matched bus bars are used for different battery terminals, then electrical resistance decreases, but manufacturing complexity increases
Solution Approach 1:
The bus bar is constructed as a composite structure with the first end made of aluminum and the second end made of copper, joined together through a joint. This composite material approach allows each end to be optimally matched to its corresponding battery terminal material (aluminum to aluminum, copper to copper), minimizing electrical resistance and improving conductivity, while accepting the increased manufacturing complexity of joining dissimilar metals.
Data Source
AI summary
A bus bar including a first end comprising a first material and a second end comprising a second material and a method of manufacture are provided. The first end is designed to be coupled to a terminal of a first battery cell of a battery module and includes a first collar disposed on the first end designed to receive and surround the terminal of the first battery cell of the battery module. The second end is designed to be coupled to a terminal of a second battery cell of the battery module and includes a second collar disposed on the second end designed to receive and surround the terminal of the second battery of the battery module. The first and second batteries of the battery module are adjacent to one another. Moreover, the bus bar includes a joint electrically and mechanically coupling the first end and the second end.