Self-Positioning Battery Busbar Without Plastic Holders
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Solution Overview
Problem
Existing battery busbar holders are complex, expensive, and pose a fire risk due to plastic components, necessitating the use of jigs and complicating battery module construction.
Innovation Solution
A battery busbar design featuring a conducting contact plate with perpendicular lips that engage with battery cell terminals, allowing secure positioning without jigs, and optionally using a compressible insulator for additional stability, with welding or mechanical fasteners for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If busbar holders are made of plastic to secure busbar positioning, then positioning accuracy is improved, but fire risk increases due to combustion fuel
Solution Approach 1:
The invention extracts and removes the plastic busbar holder component from the system entirely. Instead of using a separate plastic holder to position the busbar, the busbar itself is designed with integrated positioning lips that directly engage with the terminal perimeter, eliminating the need for plastic components and their associated fire risk while maintaining positioning accuracy.
Solution Approach 2:
The invention merges the positioning function previously performed by a separate plastic holder into the busbar structure itself. The positioning lips are integrated directly onto the busbar body, combining the conductive function and positioning function into a single metal component, thereby eliminating fire risk while preserving positioning capability.
2Reliability
If complex busbar holders with guides and clips are used to secure busbar and wiring, then securing reliability is improved, but device complexity increases
Solution Approach 1:
The invention merges multiple functions (busbar positioning, busbar securing, and wiring management) into simplified structures. The positioning lips provide both positioning and securing functions, while apertures in the busbar serve dual purposes for both mechanical fastening and wiring passage, reducing overall device complexity.
Solution Approach 2:
The busbar structure is designed with multi-functionality: the lips serve for positioning and securing, the apertures serve for both mechanical fastening (bolts/nuts) and wiring passage, and the top surface serves for welding. This universal design eliminates the need for separate specialized components.
3Manufacturing precision
If jigs and busbar carriers are used to ensure proper busbar placement, then positioning accuracy is improved, but manufacturing cost and construction time increase
Solution Approach 1:
The invention extracts and eliminates the need for external jigs and busbar carriers by incorporating self-positioning lips directly onto the busbar. These lips engage with the terminal perimeter to provide accurate positioning without requiring additional positioning tools or fixtures, thereby speeding up construction.
Solution Approach 2:
The busbar is designed to be self-positioning through its integrated lips that automatically engage with the terminal perimeter when the busbar is placed. This self-service positioning mechanism eliminates the need for external jigs or carriers to ensure proper placement, simplifying the construction process.
Data Source
AI summary
The invention relates to a battery and battery busbar. The battery busbar comprises a conducting contact plate configured to contact a terminal of a first battery cell and a terminal of a second battery cell. A lip or lips extend perpendicular to the contact plate, such that the lip or lips engage with an external perimeter of one or both of the terminal of the first battery cell and terminal of the second battery cell. This secures the busbar in position with respect to the terminals of the first battery cell and second battery cell in at least two directions. The busbar may then be secured in position relative to the terminals in a third direction, for example by welding or mechanical fasteners.