Zigzag Busbar Layout for Higher-Voltage Battery Modules
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery module designs face challenges in achieving sufficient battery voltage due to space limitations in the length direction, which restricts the number of cells in series, leading to insufficient voltage performance.
Innovation Solution
A busbar structure with conductive busbars arranged in a zigzag pattern, allowing for more cells to be connected in series within the same length space, thereby enhancing voltage performance and space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional in-line series connection is used, then the structure is simple, but the number of cells in series is limited due to length space constraints
Solution Approach 1:
The patent transitions from traditional in-line series connection (one-dimensional arrangement) to a zigzag connection pattern that utilizes both length and width dimensions. The busbars extend in the length direction while connecting cells in adjacent rows alternately, effectively using the width direction to increase the number of series connections without proportionally increasing the length space requirement.
Solution Approach 2:
The busbars are configured in a zigzag pattern rather than a straight line, creating a curved/alternating path through the cell array. This zigzag geometry allows the connection to traverse more cells within the same bounding box by utilizing diagonal and alternating directions, thereby increasing the effective path length and number of series connections.
2Power
If more cells are connected in series to increase voltage, then the voltage performance improves, but the length space requirement increases
Solution Approach 1:
The invention uses the width dimension of the battery pack to accommodate additional series connections. By connecting cells in adjacent rows alternately (first row, then second row, then first row again), the busbar utilizes the width direction to 'fold back' and continue the series connection without requiring proportional increases in length space.
Solution Approach 2:
The zigzag busbar structure effectively nests the connection path within the existing battery pack footprint. Instead of extending the length linearly, the connection path is nested within the two-dimensional array of cells, utilizing available space in both length and width directions to achieve higher voltage without increasing overall pack length.
3Ease of manufacture
If traditional in-line connection is used, then the manufacturing process is simple, but the space utilization rate is low
Solution Approach 1:
The busbar design incorporates width-directional extensions to connect cells in adjacent rows, utilizing the available width space that would otherwise be underutilized in traditional in-line connections. This dimensional expansion increases the effective use of the battery pack's footprint area.
Solution Approach 2:
The zigzag configuration of the busbar creates a more space-efficient path through the cell array compared to straight-line connections. The alternating diagonal and horizontal segments of the zigzag pattern allow the busbar to cover more ground within the same bounding box, improving space utilization.
Data Source
AI summary
Disclosed in the present disclosure is a busbar structure, including a plurality of conductive busbars arranged in a first direction, two adjacent conductive busbars being provided vertically flipped over, in which the conductive busbar includes a first conductive unit for being connected to positive electrodes of cells and a second conductive unit for being connected to negative electrodes of cells, the first conductive unit and the second conductive unit are arranged in a second direction, each conductive busbar is used to connect the cells, arranged in two adjacent zigzagged cell rows along the second direction, in series along the first direction in a zigzag pattern, respectively.