Overlapping Busbar Assembly for Flexible Battery Module Circuits
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Solution Overview
Problem
Existing battery modules have limited flexibility in electrical circuit configuration due to fixed busbar connections between adjacent batteries, making it difficult to achieve diversified electrical circuits.
Innovation Solution
A busbar assembly comprising multiple interconnected busbars and insulators that allow for the connection of batteries in various configurations, enabling the creation of diverse electrical circuits by allowing busbars to cooperate and interconnect batteries in series and parallel arrangements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If busbars only connect adjacent batteries, then the connection structure is simple, but the electrical circuit configuration is limited and cannot be diversified
Solution Approach 1:
The busbar is divided into multiple independent connecting portions (first connecting portion, second connecting portion, third connecting portion, fourth connecting portion) that can be independently connected to different battery units. This segmentation allows the busbar to establish multiple independent electrical connection paths, enabling diversified circuit configurations while maintaining a relatively simple overall structure.
Solution Approach 2:
The busbar extends in multiple spatial dimensions with connecting portions distributed at different positions along its length. By utilizing the longitudinal dimension of the busbar to position multiple connecting portions, the patent enables connections between non-adjacent batteries without increasing vertical or lateral complexity, thus achieving circuit diversity while controlling structural complexity.
2Adaptability or versatility
If multiple busbars are used to connect non-adjacent batteries, then electrical circuit diversity is achieved, but the busbar assembly becomes more complex
Solution Approach 1:
Multiple busbars are merged into a single integrated busbar structure with multiple connecting portions. Instead of using separate busbars for different connection paths, the patent combines their functions into one busbar that can simultaneously establish multiple electrical connections, thereby reducing the number of components and simplifying the overall assembly while achieving diverse circuit configurations.
Solution Approach 2:
The busbar is designed as a multi-functional component that can simultaneously serve multiple connection purposes. Its multiple connecting portions enable it to connect different battery units in various configurations (series, parallel, or combinations), making it a universal connection solution that replaces multiple specialized busbars and reduces assembly complexity.
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
This solution allows for the diversification of electrical circuits in battery modules, satisfying the requirement for flexible configurations and simplifying the connection structure, while ensuring proper insulation and heat dissipation.
Implementation Method 1
the first insulator insulates the second main portion and the first main portion
Data Source
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AI summary
The present invention provides a battery module and a busbar assembly thereof. The busbar assembly comprises a first busbar, a second busbar and a first insulator. The first busbar comprises a first connecting portion connected to a first battery unit, a second connecting portion connected to a second battery unit and a first main portion connecting the first connecting portion and the second connecting portion. The second busbar comprises a third connecting portion connected to a third battery unit, a fourth connecting portion connected to a fourth battery unit and a second main portion connecting the third connecting portion and the fourth connecting portion. The first main portion partially overlaps the second main portion, and the first insulator insulates the second main portion and the first main portion. The first battery unit, the third battery unit, the second battery unit and the fourth battery unit are arranged sequentially.