Standardized Busbar Layout for Cylindrical Cell Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The lack of standardization in busbar designs for cylindrical batteries leads to inefficiencies in production, requiring separate verification of process parameters and increased manufacturing costs due to the need for different molds and fixtures.
Innovation Solution
A standardized busbar design with integrated connecting portions that align with the central axes of battery cells, facilitating series or parallel connections, and incorporating features like positioning holes, protrusions, and fusing portions for improved reliability and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different types of busbars are processed to meet diverse battery cell requirements, then the adaptability of the busbar system is improved, but the device complexity increases due to the need for different molds and fixtures
Solution Approach 1:
The busbar is designed with a universal structure that can accommodate different battery cell types and configurations. The connecting portions are configured to adapt to various electrode arrangements while using the same mold and fixture system, allowing one busbar design to serve multiple functions across different battery module configurations.
2Reliability
If separate verification of process parameters is conducted for different busbar designs, then the reliability of the product is improved, but the loss of time increases due to repeated verification processes
Solution Approach 1:
By establishing a standardized busbar design with uniform connecting portions and dimensions, the same process parameters and verification procedures can be applied across different battery module productions. This universal verification approach ensures product reliability while eliminating the need for repeated parameter verification for each busbar type.
Solution Approach 2:
The process parameters for the standardized busbar design are verified in advance during the design and development phase. Once verified, these parameters can be directly applied to production without repeated verification, as the standardized design ensures consistent performance across different applications.
3Adaptability or versatility
If multiple types of molds and fixtures are used for processing different busbars, then the adaptability to different busbar designs is improved, but the manufacturing cost increases
Solution Approach 1:
The busbar design employs standardized dimensions, connecting portion configurations, and material specifications that can be processed using a single type of mold and fixture. This universality allows the same manufacturing equipment to produce busbars for different battery module configurations, significantly reducing the number of specialized tools required and lowering overall manufacturing costs.
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 design standardizes busbar production, reduces development costs, enhances welding precision, and increases production efficiency while ensuring safety through overload protection and preventing thermal runaway.
Implementation Method 1
The first connecting portion is welded to a positive electrode or a negative electrode of a first battery cell. The second connecting portion is connected to the first connecting portion and welded to a negative electrode or a positive electrode of a second battery cell
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A busbar (1), a battery module, and a battery pack are provided. The busbar (1) includes a first connecting portion (100) and a second connecting portion (200) connected the first connecting portion (100). The first connecting portion (100) is welded to a positive electrode or a negative electrode of a first battery cell (10). The second connecting portion (200) is configured to be welded to a negative electrode or a positive electrode of a second battery cell (20). The central axis of the first connecting portion (100), the central axis of the second connecting portion (200) and the central axis of the first battery cell (10) and the second battery cell (20) are coincided with each other.