Planar Battery Busbar Layout for Low-Height Swelling Tolerance
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Solution Overview
Problem
Existing busbars for battery modules are bulky and lack flexibility, leading to mechanical stress and limited compactness, which can be exacerbated by cell swelling and relative movement.
Innovation Solution
A planar busbar design with non-parallel cell contact legs and a divided body section, allowing the busbar body to be positioned next to cell terminals, enhancing flexibility and reducing height, while accommodating dimensional changes and mechanical loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If simple bar-shaped aluminum strips are used as busbars, then manufacturing is simple, but the battery module height increases and flexibility is reduced
Solution Approach 1:
The busbar is divided into multiple planar sections (first busbar section, second busbar section, third busbar section) that are arranged in layers. This segmentation allows the busbar to maintain a low overall height while still providing sufficient current collection area and mechanical flexibility to accommodate cell swelling.
Solution Approach 2:
The busbar design transitions from a simple one-dimensional bar shape to a multi-dimensional planar structure with sections arranged in different layers (first layer, second layer). This dimensional change enables the busbar to collect current from multiple cells while maintaining low height and providing flexibility.
2Area of stationary object
If complex three-dimensional busbar shapes are used, then current collection area increases, but mechanical stress increases and flexibility decreases
Solution Approach 1:
The busbar is segmented into multiple planar sections that can independently deform. Each section (first, second, third busbar sections) maintains a simple planar shape rather than complex 3D forms, reducing mechanical stress while collectively providing sufficient current collection area.
Solution Approach 2:
The planar busbar sections are designed to be flexible and capable of dynamic deformation to accommodate cell swelling. The sections can move relative to each other and deform elastically, providing mechanical compliance while maintaining electrical connectivity.
Data Source
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AI summary
The present invention is directed to a busbar (50) with a busbar body portion (51) that extends in an extension direction thereof with a length configured for connecting cell terminals (11, 12) of at least two battery cells (10) of a battery module (100). The busbar (50) further comprises at least two legs (52, 53) that extend from the busbar body portion (51) in a direction non-parallel to the extension direction of the busbar body portion (51) and that are configured for electrically connecting the busbar body portion (51) and cell terminals (11, 12) of battery cells (10) of the battery module (100). The busbar (50) of the invention comprise an improved elasticity, particularly between the legs (52, 53) and the busbar body portion (51) and allows for a compact battery module design with low height. The invention also relates to a battery module (100) with a plurality of battery cells (10) aligned in a lengthwise direction of the battery module (100) and a plurality of busbars (50) according to the invention for electrically interconnecting at least two battery cells (10) of the module (100).