Output Busbar Structure for Welding and Overcurrent Capacity

Solution Overview

Problem

The existing output busbars in battery packs face challenges in design due to the need for both thinness for welding to cells and thickness for overcurrent capacity when connecting adjacent battery modules in series, making it difficult and costly to manufacture molds.

Innovation Solution

The output busbar is designed with separate internal and external connection parts, where the internal connection part is thin for easy welding to cells and the external connection part is thicker for enhanced overcurrent capacity, allowing for separate mold designs and reduced production costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the output busbar is made thin to facilitate welding to cells, then welding ease is improved, but overcurrent capacity deteriorates

Engineering Contradiction:

Improvewelding easeVSAvoidovercurrent capacity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The output busbar is divided into two distinct parts: an internal connection part with smaller thickness for welding to cells, and an external connection part with larger thickness for connecting adjacent battery modules. This segmentation allows each part to be optimized independently for its specific function, resolving the contradiction between welding ease and overcurrent capacity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the output busbar are given different thicknesses according to their functional requirements. The internal connection part has smaller thickness localized for welding, while the external connection part has larger thickness localized for current carrying, achieving optimal performance in both areas without compromising either requirement.

Inventive Principle:

Principle #3Local quality

2Reliability

If the output busbar is made thick to enhance overcurrent capacity, then overcurrent capacity is improved, but welding ease deteriorates

Engineering Contradiction:

Improveovercurrent capacityVSAvoidwelding ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The output busbar is divided into two distinct parts: an internal connection part with smaller thickness for welding to cells, and an external connection part with larger thickness for connecting adjacent battery modules. This segmentation allows each part to be optimized independently for its specific function, resolving the contradiction between welding ease and overcurrent capacity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the output busbar are given different thicknesses according to their functional requirements. The internal connection part has smaller thickness localized for welding, while the external connection part has larger thickness localized for current carrying, achieving optimal performance in both areas without compromising either requirement.

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If the output busbar has uniform thickness to simplify manufacturing, then manufacturing complexity is reduced, but it cannot simultaneously satisfy both welding and overcurrent requirements

Engineering Contradiction:

Improvemold manufacturingVSAvoidfunctional adaptability

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The output busbar is divided into two distinct parts: an internal connection part with smaller thickness for welding to cells, and an external connection part with larger thickness for connecting adjacent battery modules. This segmentation allows each part to be optimized independently for its specific function, resolving the contradiction between welding ease and overcurrent capacity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the output busbar are given different thicknesses according to their functional requirements. The internal connection part has smaller thickness localized for welding, while the external connection part has larger thickness localized for current carrying, achieving optimal performance in both areas without compromising either requirement.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20250087839A1Output busbar, busbar assembly and battery pack

Publication Date: 2025.03.13 EVE ENERGY CO LTD

AI summary

An output busbar includes an internal connection part and an external connection part connected to the internal connection part. A thickness of the external connection part is greater than a thickness of the internal connection part.