Slotted Busbar Geometry for Uniform Battery Current Distribution
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Solution Overview
Problem
The existing busbar designs in battery assemblies often lead to uneven current distribution and overheating, particularly when electrode leads are attached to only a part of the busbar's outer surface.
Innovation Solution
The proposed busbar design features a plate with slots extending in one direction and spaced apart in another, incorporating a protrusion that decreases in length as it moves away from the center, along with optional step, chamfer, or inclined portions, to ensure uniform current distribution and thermal stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electrode leads are attached only to a part of the busbar's outer surface, then the attachment process is simpler, but current distribution becomes uneven and overheating occurs
Solution Approach 1:
The busbar features a protrusion with a specific geometric shape where the width varies along its length, creating different local contact areas. The wider portion provides greater contact area for electrode leads requiring higher current capacity, while the narrower portion accommodates leads with lower current requirements. This local variation in geometry optimizes current distribution across different attachment points without complicating the overall attachment process.
2Ease of manufacture
If the busbar has a uniform cross-section, then manufacturing is easier, but thermal stability and current distribution are poor
Solution Approach 1:
The busbar incorporates a protrusion that breaks the uniform cross-sectional symmetry. The protrusion extends from the main body with a width that varies along its length, creating an asymmetric geometry. This asymmetry is strategically designed to improve thermal stability by optimizing heat dissipation pathways and enhancing current distribution, while the variation in width creates different thermal zones that prevent localized overheating.
3Ease of manufacture
If the protrusion length is constant along the busbar, then manufacturing is simpler, but current distribution uniformity deteriorates
Solution Approach 1:
The protrusion is designed with a varying width parameter along its length rather than a constant cross-section. The width changes systematically from one end to the other, creating zones with different contact capabilities. This parameter variation allows the single protrusion structure to serve multiple functional purposes: providing optimal contact area for different electrode leads while maintaining uniform current distribution across the busbar surface.
Data Source
AI summary
The present disclosure relates to a busbar including a plate; and a plurality of slots formed at the plate, each extending along a first direction, and spaced apart from each other along a second direction which is different from the first direction, wherein the plate includes a body in which the plurality of slots are formed; and a first protrusion formed by extending at least a part of the body along the first direction, and a battery assembly including the same.