Plated Copper Busbar Assembly for Reliable Battery Module Welding
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Solution Overview
Problem
Vehicle traction batteries face challenges in minimizing size and weight while maintaining high energy and peak current output, with a need for reliable electrical connections to prevent module malfunction due to faulty connections.
Innovation Solution
A busbar assembly comprising a terminal collection plate and a lattice portion made of copper plated with nickel and/or titanium, allowing for laser welding connections that reduce electrical resistance and oxidization, facilitating efficient and repeatable manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper is used for the lattice portion, then electrical conductivity is improved, but weight and cost increase
Solution Approach 1:
The lattice portion uses copper plated with nickel and/or titanium, creating a composite material structure that combines the high electrical conductivity of copper with the lightweight properties and oxidation resistance of the plated layers, resolving the contradiction between conductivity and weight
2Reliability
If copper is used for the lattice portion, then electrical conductivity is improved, but susceptibility to oxidisation increases
Solution Approach 1:
The copper lattice portion is plated with nickel and/or titanium to create a protective outer layer that prevents oxidation of the copper, while maintaining the electrical conductivity benefits of the copper base material
Solution Approach 2:
The nickel and/or titanium plating acts as an intermediary protective layer between the copper and the oxidizing environment, preventing direct contact between oxygen and the copper surface
3Manufacturing precision
If laser welding is used to connect copper and aluminium, then manufacturing precision is improved, but weld quality deteriorates due to material incompatibility
Solution Approach 1:
The nickel and/or titanium plating on the copper lattice portion serves as an intermediary layer that facilitates welding between copper and aluminium, enabling laser welding to proceed effectively despite the inherent incompatibility between these two materials
4Volume of moving object
If busbar assembly size is reduced, then vehicle weight and volume are minimized, but electrical connection reliability may worsen
Solution Approach 1:
The lattice portion uses thin plated copper structure that provides effective electrical connection with minimal volume, allowing the busbar assembly to be compact while maintaining connection reliability through the high conductivity of copper and the stability of the plated layers
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
The solution results in a lightweight, low-cost busbar assembly with improved weld quality and reduced electrical resistance, enhancing the reliability and efficiency of battery modules and packs.
Implementation Method 1
the metallic layer may reduce reflectivity at infrared wavelengths, which may be particularly important in the event that the connections between the terminal collection plate and the lattice portion are made by an infrared laser welding system
Implementation Method 2
The metallic layer may also help to reduce oxidisation of the outer surfaces of the lattice portion, which improves weld quality and reduces the overall electrical resistance of the busbar assembly
Implementation Method 3
the lattice portion is welded to the terminal collection plate. The lattice portion may be laser welded to the terminal collection plate, for example using an infrared laser welding system
Data Source
AI summary
Embodiments of the present invention provide components for batteries, and methods of manufacture of batteries or battery modules. In some embodiments, the methods comprise producing a plurality of sub-assemblies comprising a group of mechanically-connected cells (1000) and an associated busbar assembly (206), and subsequently assembling the sub-assemblies within a housing and electrically connecting the busbar assemblies (206) to produce a battery module.