Description:TECHNICAL FIELD
[0001] The present disclosure generally relates to the field of electrical power systems. More particularly, the present disclosure provides a design and implementation of assemblies for connecting busbars to cell terminals.

BACKGROUND
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] In the field of battery technology, specifically concerning the connection of busbars to cell terminals, several technologies are used to ensure reliable electrical and mechanical connections. These technologies include laser welding, spot welding, ultrasonic welding, wire bonding, and bolting. Each method has its own set of advantages and limitations, often chosen based on the specific type of battery cell and the design of the cell terminals. For example, prismatic lithium-ion (Li-ion) cells, which are commonly used in various applications such as electric vehicles and energy storage systems, typically feature an internal threaded arrangement at their terminals to facilitate connections with busbars.
[0004] Among the various methods, bolting is one of the most widely adopted techniques due to its simplicity and ease of assembly. However, this method has significant limitations, particularly concerning the effective contact area between the busbar and the cell terminal. The bolted connection typically provides a limited contact surface, which can increase the electrical resistance at the interface. This increased resistance is problematic because it can lead to the formation of hotspots—localized areas of elevated temperature. These hotspots are detrimental as they can accelerate the degradation of the battery cells, reduce efficiency, and increase the risk of thermal runaway, a condition where excessive heat leads to catastrophic failure of the cell.
[0005] The problem of limited contact area also contributes to higher current density at the point of contact between the busbar and the cell terminal. High current density can exacerbate the generation of heat, further contributing to the formation of hotspots and potentially leading to thermal management issues within the battery pack.
[0006] Furthermore, the mechanical reliability of bolted connections is a concern in environments subject to continuous vibrations or shock loads, such as those found in automotive or industrial applications. Vibrations and shocks can cause the bolted connections to loosen over time, which can compromise the electrical continuity and mechanical stability of the connection. This vulnerability to loosening or mechanical failure increases the likelihood of disconnections or faults, which can have serious implications for the performance and safety of the battery system.
[0007] Overall, while bolting is a common method for connecting busbars to cell terminals, its limitations highlight the need for improved technologies that can provide better contact area, reduced resistance, and enhanced mechanical stability, particularly in demanding operational environments.
[0008] Therefore, there is a need to overcome the above-mentioned problems by bringing a solution to linkage of busbar and cell terminals with an arrangement providing a better surface contact for current transfer and heat dissipation in between the cells.

OBJECTS OF THE PRESENT DISCLOSURE
[0009] Some of the objects of the present disclosure, which at least one embodiment herein satisfy are as listed herein below.
[0010] A general object of the present disclosure is to provide an improved method for connecting busbars to cell terminals that increases the contact area at the interface, thereby reducing electrical resistance and minimizing the formation of temperature hotspots.
[0011] Another object of the present disclosure is to enhance the electrical performance of the connection by reducing current density at the busbar and cell terminal interface,
[0012] Another object of the present disclosure is to improve thermal management by integrating features that facilitate better heat dissipation from the busbar and cell terminal interface.
[0013] Another object of the present disclosure is to develop a connection method that provides greater mechanical stability and resilience, particularly in environments subject to continuous vibrations and shock loads, reducing the risk of connection loosening or failure.
[0014] Another object of the present disclosure is to ensure that the new connection method is easy to assemble and maintain reducing the complexity and time required for installation and servicing, thereby improving overall system reliability and maintenance efficiency.

SUMMARY
[0015] Various aspects of present disclosure relates to the field of electrical power systems. More particularly, the present disclosure provides a design and implementation of assemblies for connecting busbars to cell terminals.
[0016] An aspect of the present disclosure pertains to an assembly may be configured to facilitate a connection of busbars and cell terminals, including a component featuring a threaded mounting mechanism for securing the busbars to the cell terminals in one or more battery cells with a preset torque control; including three zones of: zone A configured to accommodate with the threaded mounts for robust attachment to the cell terminals; zone B configured to arrange a spring-loaded contact system between the busbar and the cell terminal; and zone C configured to serve as a temperature sensor, providing effective heat dissipation to maintain optimal operational temperatures.
[0017] In an aspect, the torque application step may be configured to include the use of a torque wrench calibrated to the preset torque values specified for the busbars and the cell terminals.
[0018] In another aspect, the component may be configured to include visual and mechanical guides to assist in the correct alignment and positioning of the busbars during installation.
[0019] In an aspect, the component features an integrated indicator and gauge for verifying the torque values after the busbars are mounted.
[0020] In another aspect, the component is made from a composite material combining high-strength polymers with thermal conductivity enhancers to balance mechanical strength and thermal performance.
[0021] In an aspect, the component may be configured to include color-coded and labeled sections to aid in the correct assembly and alignment of the busbars and cell terminals.
[0022] In an aspect, the component may be configured to include a locking mechanism that engages automatically when the busbars reach the specified torque, preventing loosening over time.
[0023] In an aspect, the zone A includes self-aligning threads that automatically adjust to fit one or more sizes of the cell terminals, enhancing ease of installation, the zone B includes a spring-loaded contact system to maximize a contact area that maintains consistent pressure between the busbar and cell terminal, improving electrical performance, and the zone C includes an embedded temperature sensor serve as a heat sink that monitors heat levels and provides real-time feedback to ensure optimal thermal management.
[0024] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0025] The accompanying drawings are included to provide a further understanding of the present disclosure and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure. The diagrams are for illustration only, which thus is not a limitation of the present disclosure.
[0026] In the figures, similar components and/or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label with a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.
[0027] FIG. 1A illustrate an exemplary architecture for the proposed cell terminal linkage of the battery pack, in accordance with an embodiment of the present disclosure.
[0028] FIG. 1B illustrates an exemplary architecture for the proposed busbar linkage of the battery pack, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION
[0029] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims.
[0030] Exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. This disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. These embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the disclosure to those of ordinary skill in the art. Moreover, the present disclosure relates to the field of electrical power systems. More particularly, the present disclosure provides a design and implementation of assemblies for connecting busbars to cell terminals.
[0031] According to embodiments illustrated herein, the proposed disclosure introduces a specialized component designed to connect busbars to cell terminals in battery systems, addressing critical issues related to thermal management and mechanical stability. One of the primary functions of this component is to act as a heat sink, effectively dissipating localized heat generated at the cell terminals during operation. By efficiently transferring this heat away from the terminals, the component prevents the formation of temperature hotspots, which are known to degrade cell performance and safety. This enhanced thermal management allows for higher charge and discharge currents from the lithium-ion cells, as the component provides an additional layer of thermal protection at the interface between the busbar and cell terminal.
[0032] Furthermore, the component is engineered to withstand mechanical stresses such as vibrations and sudden impacts, making it particularly valuable in applications where durability and reliability are critical. The disclosure not only improves the electrical and thermal performance of battery systems but also enhances their safety and longevity.
[0033] The manner in which the proposed system works is described in further details in conjunction with FIGs. 1A – 1B. It may be noted that these figures are only illustrative, and should not be construed to limit the scope of the subject matter in any manner.
[0034] FIG. 1A illustrates an exemplary architecture for the proposed cell terminal linkage of the battery pack, and FIG. 1B illustrates an exemplary architecture for the proposed busbar linkage of the battery pack, in accordance with an embodiment of the present disclosure.
[0035] Referring to FIG. 1A, a configuration and arrangement of the proposed cell terminal linkage 100 (interchangeably referred to as an assembly 100, hereinafter) designed to optimize the connection between busbars 110 and cell terminals 104, 106. In the architecture shown, the focus is on how the cell terminals 104, 106 interface with the busbars 110 through a specialized component that addresses common issues such as thermal management and mechanical stability.
[0036] Referring to FIG. 1B, an exemplary architecture for the busbar linkage 100B within the battery pack, as outlined in an embodiment of the present disclosure. The referred figure provides a detailed view of how the busbars 110 may be integrated into the battery pack, focusing on the assembly 100 designed to optimize performance and reliability.
[0037] In an exemplary embodiment, a component 108 under consideration is a specialized intermediary device designed to facilitate the secure and efficient connection of the busbars 110 to the cell terminals 104, 106 in battery pack. It is bolted directly onto the cell terminals 104, 106, leveraging a threaded mounting system to ensure a robust mechanical bond. The bolted connection is crucial for maintaining the stability and integrity of the electrical junction, particularly in environments where the battery is subject to vibrations or mechanical shocks. The busbars 110, which serve as conduits for electrical current, are mounted onto the component 108 and tightened according to precise torque specifications. The preset torque values are critical to ensure that the connection is neither too loose, which could lead to increased electrical resistance and potential disconnections, nor too tight, which can damage the component 108.
[0038] The assembly 100 described in FIG. 1 may be configured to include the cell terminals 104 and 106 of a cell 102, the proposed component 108, and the busbar 110. The component 108 itself is divided into three distinct functional zones, each and every zone playing a specific role in enhancing the overall performance and reliability of the connection.
[0039] In an exemplary embodiment, a zone A is the point of interface with the cell terminals 104 and 106. The zone A may be configured to utilize a threaded mounting system, which aligns with the internal threading present on the cell terminals 104 and 106. The design of zone A can ensure that the component 108 is firmly anchored, providing a stable platform for the busbar 110 connection. The secure attachment is essential for maintaining the integrity of the electrical and mechanical connections under one or more operational conditions.
[0040] In an exemplary embodiment, a zone B may be strategically designed to maximize the contact area between the busbar 110 and the cell terminals 104 and 106. The increased contact area is a critical feature, as it reduces the electrical resistance at the interface. By doing so, the zone B may enhance the efficiency of current transfer, minimizes energy losses, and helps in maintaining a consistent electrical performance. The design may include specialized surface treatments or geometrical configurations that facilitate a larger, more effective contact surface. This optimization not only improves electrical conductivity but also helps in evenly distributing the current, thereby reducing the likelihood of localized heating and the formation of hotspots, which can degrade battery performance and safety.
[0041] In an exemplary embodiment, a zone C can function as a heat sink, a crucial aspect of the component’s 108 design. The zone C is constructed from materials with high thermal conductivity, such as aluminum or copper, which are effective at absorbing and dissipating heat. The design might include features like fins or additional surface area to enhance heat dissipation. By efficiently managing the thermal energy generated during the operation of the battery, the Zone C can help to maintain lower temperatures at the busbar-cell terminal interface. This is particularly important in preventing thermal runaway, a dangerous condition where excessive heat leads to a catastrophic failure of the battery cells.
[0042] Generally the component 108 may be engineered not only to provide a reliable electrical and mechanical connection but also to address critical issues related to thermal management and mechanical stability. The assembly 100 design can ensure that the connection remains secure, efficient, and safe, even in challenging operating environments. The integration of features across the three zones makes the component 110 a key innovation for enhancing the performance and durability of battery pack, particularly in applications that demand high reliability and safety standards.
[0043] In summary, the present disclosure proposes an advanced linkage system or an assembly for connecting busbars to cell terminals, aimed at addressing key challenges in battery systems. The design focuses on maximizing the surface contact area between the busbars and cell terminals, which is crucial for enhancing electrical conductivity and ensuring efficient current transfer. By increasing the contact area, the system significantly reduces electrical resistance at the interface, thereby improving the overall charge and discharge rates of the cells. Additionally, the invention incorporates features that facilitate superior heat dissipation, effectively managing the thermal energy generated during battery operation. This improved thermal management helps in preventing thermal hotspots, which can lead to cell degradation and reduce the battery's lifespan. The invention’s emphasis on both electrical and thermal optimization makes it a superior alternative to conventional cell linkage methods, which often suffer from limited contact areas and inadequate heat dissipation capabilities. Overall, this linkage system not only enhances the performance and reliability of battery packs but also contributes to their safety and durability, making it particularly valuable in high-demand applications such as electric vehicles and large-scale energy storage systems.
[0044] The above-described features, configurations, effects, and the like are included in at least one of the embodiments of the present invention, and should not be limited to only one embodiment. In addition, the features, configurations, effects, and the like as illustrated in each embodiment may be implemented with regard to other embodiments as they are combined with one another or modified by those skilled in the art. Thus, content related to these combinations and modifications should be construed as including in the scope and spirit of the invention as disclosed in the accompanying claims.
[0045] Various embodiments of the methods and systems for real time solar panel level monitoring system identify faults in the solar panels at an early stage, allowing for quick repairs before the faults become more serious and affect the overall performance of the solar plant. However, it should be apparent to those skilled in the art that modifications in addition to those described, are possible without departing from the inventive concepts herein. The embodiments, therefore, are not restrictive, except in the spirit of the disclosure. Moreover, in interpreting the disclosure, all terms should be understood in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps, in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced.
[0046] Those skilled in the art will appreciate that any of the aforementioned steps and/or system modules may be suitably replaced, reordered, or removed, and additional steps and/or system modules may be inserted, depending on the needs of a particular application. In addition, the systems of the aforementioned embodiments may be implemented using a wide variety of suitable processes and system modules and is not limited to any particular computer hardware, software, middleware, firmware, microcode, or the like.
[0047] The claims can encompass embodiments for hardware, software, or a combination thereof.
[0048] It will be appreciated that variants of the above disclosed, and other features and functions or alternatives thereof, may be combined into many other different systems or applications. Presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art, which are also intended to be encompassed by the following claims.

ADVANTAGES OF THE INVENTION
[0049] The proposed disclosure overcomes the above drawback, limitations, and shortcomings associated with the existing gaming practices.
[0050] The present disclosure increased surface contact area between busbars and cell terminals reduces electrical resistance, leading to more efficient current transfer.
[0051] The present disclosure includes features that act as heat sinks, effectively dissipating heat generated at the connection interface
[0052] The present disclosure provides heat management more efficiently and preventing thermal hotspots, the invention reduces the risk of thermal runaway, a condition that can lead to catastrophic battery failure.
[0053] The present disclosure provides the optimized electrical and thermal performance reduces wear and tear on battery cells, extending the operational life of the battery pack.
[0054] The present disclosure provides preset torque values for securing connections simplifies the assembly process and ensures consistent, reliable connections.
[0055] The present disclosure improves the efficiency and longevity of battery pack, which can lead to cost savings over time, reducing the need for frequent replacements and maintenance.
[0056] The present disclosure provides the improved thermal and electrical properties make the present disclosure ideal for applications that require high power density and reliability, such as electric vehicles, industrial machinery, and renewable energy systems.
, Claims:1. An assembly (100) that facilitates a connection of busbars (110) and cell terminals (104, 106), comprising:
a component (108) features a threaded mounting mechanism for securing the busbars (110) to the cell terminals (104, 106) in one or more battery cells with a preset torque control comprising three zones of:
zone A configured to accommodate with the threaded mounts for robust attachment to the cell terminals (104, 106);
zone B configured to arrange a spring-loaded contact system between the busbar (110) and the cell terminal (104, 106); and
zone C configured to serve as a temperature sensor, providing effective heat dissipation to maintain optimal operational temperatures.
2. An assembly (100) as claimed in claim 1, wherein the torque application step comprises the use of a torque wrench calibrated to the preset torque values specified for the busbars (110) and the cell terminals (104, 106).
3. An assembly (100) as claimed in claim 1, wherein the component (108) comprises visual and mechanical guides to assist in the correct alignment and positioning of the busbars (110) during installation.
4. An assembly (100) as claimed in claim 1, wherein the component (108) features an integrated indicator and gauge for verifying the torque values after the busbars (110) are mounted.
5. An assembly (100) as claimed in claim 1, wherein the component (108) is made from a composite material combining high-strength polymers with thermal conductivity enhancers to balance mechanical strength and thermal performance.
6. An assembly (100) as claimed in claim 1, wherein the component (108) comprises color-coded and labeled sections to aid in the correct assembly and alignment of the busbars (110) and the cell terminals (104, 106).
7. An assembly (100) as claimed in claim 1, wherein the component (108) comprises a locking mechanism that engages automatically when the busbars (110) reach the specified torque, preventing loosening over time.
8. An assembly (100) as claimed in claim 1, wherein the zone A comprises self-aligning threads that automatically adjust to fit one or more sizes of the cell terminals (104, 106), enhancing ease of installation.
9. An assembly (100) as claimed in claim 1, wherein the zone B comprises a spring-loaded contact system to maximize a contact area that maintains consistent pressure between the busbar (110) and the cell terminals (104, 106), improving electrical performance.
10. An assembly (100) as claimed in claim 1, wherein the zone C comprises an embedded temperature sensor serve as a heat sink that monitors heat levels and provides real-time feedback to ensure optimal thermal management.