Laminated busbar with shielding for battery systems

Abstract

The present invention is entitled a laminated busbar with a shielding layer for a battery system. The present invention discloses a laminated busbar assembly, which includes one or more busbars configured to be electrically coupled to a plurality of battery cells, one or more insulating layers arranged adjacent to the one or more busbars, and a steel layer arranged between the one or more busbars and the plurality of battery cells. The steel layer is configured to shield the one or more busbars from thermal events associated with one or more of the plurality of battery cells. The thermal event may include debris, hot gases, sparks, ashes or other emissions. Each battery cell includes a respective vent end facing the steel layer, with an electrical terminal located at the vent end. The laminated busbar is a laminated stack that may include two busbars forming a DC bus, wherein an insulator is arranged between the busbars and between the steel layer and the proximal busbar.

Description

[0001] introduction

[0002] The present disclosure relates to laminated bus bars for battery systems, and more particularly to bus bars having shielding layers to protect against thermal events. Summary of the invention

[0003] In some embodiments, the present disclosure relates to a laminated busbar assembly, the laminated busbar assembly comprising at least one busbar, an insulating layer and a steel layer. The at least one busbar is configured to be electrically coupled to a plurality of battery cells. The insulating layer is arranged adjacent to the at least one busbar and is a dielectric. The steel layer is arranged adjacent to the insulating layer and is arranged between the at least one busbar and the plurality of battery cells. The steel layer is configured to shield the at least one busbar from thermal events associated with one or more of the plurality of battery cells. The plurality of battery cells each include a corresponding vent end facing the steel layer.

[0004] In some embodiments, the at least one bus bar comprises an aluminum material, a copper material, any other suitable conductive material, or any combination thereof.

[0005] In some embodiments, a portion of the steel layer is separated from the insulating layer by an air gap. In some embodiments, the laminated busbar assembly includes one or more gaps made of a dielectric material extending through the air gap.

[0006] In some embodiments, the laminated bus bar assembly is configured to be installed as a single piece. For example, the laminated bus bar assembly can be handled as a single component.

[0007] In some embodiments, the at least one busbar includes a first busbar and a second busbar, the insulation layer is disposed between the second busbar and the steel layer, and the laminated busbar assembly includes a second insulation layer disposed between the first busbar and the first side of the second busbar.

[0008] In some embodiments, the present disclosure relates to a battery system, the battery system comprising a first plurality of battery cells arranged in a first battery module, a second plurality of battery cells arranged in a second battery module, and a stacked busbar assembly arranged and configured to be electrically coupled to the first plurality of battery cells and the second plurality of battery cells. The first plurality of battery cells and the second plurality of battery cells each include a corresponding vent end. For example, the electrical terminals may be concentrically arranged at the vent end, wherein the area between the terminals is configured as a vent. The first battery module and the second battery module are arranged adjacent to each other and electrically coupled in series. The stacked busbar assembly is arranged above a first portion of the first battery module facing the corresponding vent end. The stacked busbar comprises: a first busbar configured to be electrically coupled to the first plurality of battery cells and the second plurality of battery cells; a second busbar configured to be electrically coupled to the first plurality of battery cells and the second plurality of battery cells; a first insulating layer arranged between the first busbar and the second busbar; a second insulating layer arranged adjacent to the second busbar; and a steel layer arranged adjacent to the second layer and arranged between the second busbar and the plurality of battery cells. The steel layer is configured to shield the first bus bar and the second bus bar from thermal events associated with one or more battery cells in the first plurality of battery cells. In some embodiments, the laminated bus bar assembly is installed in a battery system as a single piece.

[0009] In some embodiments, the steel layer is configured to be electrically grounded.

[0010] In some embodiments, the laminated busbar includes a third insulating layer disposed adjacent to the first busbar and opposite the first insulating layer.

[0011] In some embodiments, the present disclosure relates to a battery system comprising a plurality of battery modules and a stacked busbar assembly, each battery module comprising a corresponding plurality of battery cells. The battery modules are electrically coupled via a plurality of busbars, and each battery cell comprises a corresponding venting end. The stacked busbar assembly comprises at least one busbar among a plurality of busbars. The stacked busbar assembly is configured to be electrically coupled to the first plurality of battery cells and the second plurality of battery cells. The at least one busbar is arranged above a first portion of the first battery module. The stacked busbar assembly also includes an insulating layer arranged adjacent to the at least one busbar, and a steel layer arranged adjacent to the at least one insulating layer and arranged between the at least one busbar and the plurality of battery cells. The steel layer is configured to shield the at least one busbar from thermal events associated with one or more battery modules in the plurality of battery modules. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The present disclosure according to one or more various embodiments is described in detail with reference to the following drawings. The drawings are provided for illustrative purposes only and only show typical or exemplary embodiments. These drawings are provided to facilitate understanding of the concepts disclosed herein, and these drawings should not be considered as limitations on the breadth, scope or applicability of these concepts. It should be noted that for clarity and ease of description, these drawings are not necessarily drawn to scale.

[0013] Figure 1 shows a cross-sectional front view of an illustrative battery system having a laminated bus bar assembly including a shielding layer according to some embodiments of the present disclosure;

[0014] Figure 2 shows a cross-sectional front view of an exemplary battery system having a laminated bus bar assembly according to some embodiments of the present disclosure;

[0015] Figure 3 shows a cross-sectional front view of an exemplary battery system experiencing a thermal event according to some embodiments of the present disclosure;

[0016] Figure 4 shows a perspective view of an exemplary battery system having a laminated bus bar assembly according to some embodiments of the present disclosure;

[0017] Figure 5 shows a top view of an illustrative battery system having a plurality of battery modules according to some embodiments of the present disclosure;

[0018] Figure 6 shows a cross-sectional side view of an exemplary laminated busbar assembly having layers according to some embodiments of the present disclosure;

[0019] Figure 7 shows a cross-sectional side view of an exemplary laminated busbar assembly having more than one busbar according to some embodiments of the present disclosure;

[0020] Figure 8 shows a cross-sectional side view of another exemplary laminated bus bar assembly having more than one bus bar according to some embodiments of the present disclosure; and

[0021] Fig. 9 A cross-sectional side view of another illustrative laminated busbar assembly having more than one shield is shown, according to some embodiments of the present disclosure. DETAILED DESCRIPTION

[0022] In some embodiments, the battery system includes one or more battery modules, each of which includes a plurality of battery cells. The subgroups of the battery cells are electrically connected in parallel, and the subgroups are electrically connected in series through a series of current collectors (or busbars). For example, the terminal current collector or busbar exhibits a potential difference that defines a DC bus. In some embodiments, a switch component, a fuse component, a busbar carrying the full voltage of the battery module, any other suitable power electronic device, any other suitable component, or any combination thereof that can be arranged on or near the battery module. In some embodiments, the stacked busbar is arranged on the side (e.g., front, back, or any lateral surface) of the battery system for forming a suitable electrical connection between the components. In some such embodiments, the stacked busbar extends over a portion of the battery module, and can therefore be arranged over one or more battery cells (e.g., the venting end of the battery cell). For example, if the battery cell undergoes a thermal event, the nearby busbar may be damaged. Therefore, it may be desirable to provide a stacked busbar arranged above the battery module, which is shielded from the battery cell.

[0023] In an illustrative example, a cylindrical battery cell may include a sheath (e.g., steel) covering a first axial end and a cylindrical side (e.g., a lateral side) of the battery cell. The sheath ends at an edge at a second axial end of the battery cell. The second axial end also typically has a button electrode and a vent structure located between the edge of the sheath and the button electrode (e.g., both the positive electrode and the negative electrode are arranged in a concentric pattern at the second axial end). When the battery cell overheats or otherwise experiences a thermal event, gas, grit, flames, sparks, or a combination thereof may escape through the vent structure. Therefore, components facing the vent end of the battery cell may be damaged during a thermal event.

[0024] In some embodiments, the present disclosure relates to a laminated busbar having a steel layer (e.g., an outer layer). For example, the steel layer may be positioned on a side of the laminated busbar facing the battery module (e.g., closest to the battery cells). In some embodiments, the steel layer is constructed and arranged to provide thermal protection for the laminated busbar in the event that a battery cell disposed below the laminated busbar experiences a thermal event.

[0025] Figure 1A cross-sectional front view of a portion of an exemplary battery system 100 having a stacked busbar assembly 121 including a shielding layer 130 according to some embodiments of the present disclosure is shown. The battery system 100 includes a battery module 110 and a stacked busbar assembly 121. The stacked busbar assembly 121 includes a busbar stack 120, a shielding layer 130, and an interface 140, which may include but does not necessarily include a space (e.g., an air gap). As shown, the shielding layer 130 of the stacked busbar assembly 121 and the battery module 110 are separated by a space 141. The battery module 110 includes battery cells 111, 112, 113, 114, 115, and 116 (e.g., which may represent a subgroup of battery cells of the battery module 110). As shown, each of the battery cells 111-116 may include a cylindrical battery cell, wherein the positive terminal and the negative terminal are both arranged at the top (e.g., toward the stacked busbar assembly 121, as shown). The laminated busbar assembly 121 can be configured to be installed as a single piece. For example, the shielding layer 130 and the busbar stack 120 can be adhered or otherwise bonded to each other to form a laminated stack that can be installed as a unit in the battery system 100.

[0026] As shown, the busbar stack 120 includes several layers. For example, the layers of the busbar stack 120 may include busbars (e.g., conductive elements for distributing or collecting current from multiple battery cells), insulating layers (e.g., dielectric materials), or any combination thereof. For example, one or more layers of the busbar stack 120 may include conductive materials (e.g., copper, aluminum, carbon fiber), while one or more other layers may include electrically insulating materials to provide electrical insulation between conductive layers or portions of the busbar stack 120.

[0027] In some embodiments, for example, the shielding layer 130 includes a steel layer (e.g., a plate or sheet). In some embodiments, an intermediate layer (e.g., interface 140 as shown) is positioned between the shielding layer 130 and the busbar stack 120. Layer 140 may include, for example, an air gap, a gap, a thermal insulator, any other suitable component or material, or any combination thereof. In some embodiments, for example, the intermediate layer includes a combination of an air gap and a gap. In some embodiments, the intermediate layer includes a thermal insulation layer, such as a dielectric sheet. In some embodiments, the thickness and properties of the layer interface 140 and the shielding layer 130 are sufficient to provide thermal protection from battery cell thermal events (e.g., from one or more battery cells in the battery cells 111-116). For example, the interface 140 may include an adjacent interface, wherein the shielding layer 130 is adjacent to the busbar stack 120. In another example, the interface 140 may include a gapped interface, wherein the shielding layer 130 is spaced apart from the stacked busbar 120 (e.g., an insulator, an air gap, a gap, or a combination thereof is arranged therebetween). In some embodiments, for example, the interface 140 can be approximately 0.5 mm thick. In some embodiments, for example, when the battery system is configured for use in an electric vehicle, the shielding layer 130 can be grounded to a vehicle ground.

[0028] For illustration, the battery system 100 may implement an arrangement of a stacked busbar assembly 121 above the battery module 110. In some embodiments, the shielding layer 130 is configured to provide thermal protection to the busbar stack 120 without requiring separate components or additional spacing between components. In some embodiments, the shielding layer 130 may be included as part of the busbar stack 120 assembled using any suitable manufacturing process (e.g., to reduce assembly time for assembling the battery system 100). In some embodiments, the battery system 100 provides a thermally protected busbar with a minimum packaging height (e.g., to increase packaging density).

[0029] The space 141 may include any suitable thickness, as well as intervening materials located between the stacked busbar assembly 121 and the battery module 110. For example, the space 141 may include an air gap, an insulating layer (e.g., a thermal insulator, an electrical insulator, or both), one or more gaps, any other suitable gaps or layers, or any combination thereof. For illustration, in some embodiments, the stacked busbar assembly 121 is assembled and then installed as a unit above the battery module 110. For further explanation, in some embodiments, the battery module 110, the stacked busbar assembly 121, or both may include an electrical insulator in at least a portion of the space 141 (e.g., arranged above a current carrier, a grounding member, or other possible electrical shorting location).

[0030] For illustration, a stacked busbar assembly (e.g., stacked busbar assembly 121) can include multiple layers of electrical conductors and dielectrics arranged to provide routing for electrical current and isolation between busbars and from other components. The layers can be adhered (e.g., with any suitable adhesive having any suitable electrical properties), pressed (e.g., pressed to a specified pressure or thickness), processed (e.g., heated, chemically treated, trimmed), or otherwise combined to form a stacked busbar assembly that can be handled as a single component. The stacked busbar assembly can provide a structurally rigid, contoured, and compact component for routing and isolating current-carrying components (e.g., busbars). For example, for illustration, because the stacked busbar assembly can be substantially planar (e.g., a plane having a relatively small thickness relative to the in-plane dimensions) and can be shaped to fit the available space in a battery system, the assembly can be more easily installed to maintain a compact design.

[0031] To further illustrate, a laminated busbar assembly (e.g., laminated busbar assembly 121) may include multiple electronic conductor layers separated from each other by layers of dielectric material (e.g., polyimide (PI) and polyethylene terephthalate (PET)) between each layer. The conductive layers and dielectric layers may be arranged, pressed, and baked at high temperatures to obtain an integrated laminated assembly.

[0032] Figure 2 A cross-sectional front view of an exemplary battery system 200 having a stacked busbar assembly 221 according to some embodiments of the present disclosure is shown. The battery system 200 includes a battery module 210 and a busbar assembly 221, which includes a busbar stack 220 and a shielding layer 230. As shown, the busbar stack 220 and the shielding layer 230 are integrated into the stacked busbar assembly 221 and are separated by a layer 240. As shown, the stacked busbar assembly 221 and the battery module 210 are separated by a space 241. The battery module 210 includes battery cells 211, 212, 213, 214, 215 and 216 (e.g., which may represent a subset of battery cells of the battery module 210). For example, the battery module 210 may be similar to Figure 1 In another example, the busbar stack 220 may be similar to Figure 1 The busbar stack 120 of the battery system 200. The stacked busbar assembly 221 can be configured to be installed as a single workpiece. For example, the shielding layer 230 and the busbar stack 220 can be adhered or otherwise bonded to each other to form a stack that can be installed as a unit in the battery system 200.

[0033] As shown, the busbar stack 220 includes several layers, such as, for example, one or more busbars (e.g., conductive elements for distributing or collecting current from a plurality of battery cells), one or more insulating layers (e.g., insulating layers of dielectric material), or any combination thereof. For illustration, the stacked busbar assembly 221 may include two busbars defining an electrical DC bus, the two busbars being separated by a dielectric layer and insulated from the shielding layer 230 and any other suitable components by an additional dielectric layer.

[0034] In some embodiments, for example, the shielding layer 230 includes a steel bracket configured as a part of the stacked busbar 221 (e.g., attached to the busbar stack 220). In some embodiments, an intermediate layer (e.g., layer 240 as shown) is formed between the shielding layer 230 and the busbar stack 220. The layer 240 may include, for example, an air gap, a gap, a thermal insulator, any other suitable component or material, or any combination thereof. In some embodiments, for example, the intermediate layer may include a combination of an air gap and a gap. In some embodiments, the thickness and properties of the layer 240 and the shielding layer 230 are sufficient to provide thermal protection from battery cell thermal events (e.g., from one or more of the battery cells 211-216). In some embodiments, for example, the layer 240 may be approximately 0.5 mm thick. For illustration, the layer 240 is formed by a gap region of the shielding layer 230 extending away from the busbar stack 220 (e.g., the gap may be integrated into the shielding layer 230 or separate the component from the shielding layer). In some embodiments, for example, when the battery system is configured for an electric vehicle, the shielding layer 230 can be grounded to the vehicle ground. The shielding layer 230 can include any suitable material, have any suitable thickness and shape, and be arranged at any suitable distance from the battery module 210 (e.g., adjacent to or spaced apart from the battery module).

[0035] Figure 3 A cross-sectional front view of an exemplary battery system 300 experiencing a thermal event 390 according to some embodiments of the present disclosure is shown. The battery system 300 includes a battery module 310 and a stacked busbar assembly 321, which includes a busbar stack 320 and a shielding layer 330. As shown, the busbar stack 320 and the shielding layer 330 meet at an interface 340. The battery module 310 includes battery cells 311, 312, 313, 314, 315, and 316 (e.g., which may represent a subset of battery cells of the battery module 310). For example, the battery module 310 may be similar to Figure 1 The battery module 110, the busbar stack 320 may be similar to Figure 1 The busbar stack 120, and the shielding layer 330 may be similar to Figure 1Shielding layer 130. Shielding layer 330 can protect busbar stack 320 from sparks (e.g., ionized gaseous materials), ash, debris, hot jets, hot gases, radiant heat transfer, convective heat transfer, or a combination thereof. Interface 340 may include an insulator, an air gap, a gap, or a suitable combination thereof, which may provide additional shielding for busbar stack 320 from convective heat transfer, conductive heat transfer, or a combination thereof. The stacked busbar assembly 321 is separated from the battery module 310 by space 341. Space 341 may include a contact interface (e.g., no spacing), an air gap, a gap, or a combination thereof.

[0036] In some cases, one or more battery cells may experience a thermal event. For example, during operation, a battery cell may experience venting, fire, thermal runaway, overheating, arcing (e.g., generating sparks or plasma), electrical shorting, any other failure mode that may create a destructive environment for the busbar, or any combination thereof. Figure 3 As shown, the battery cell 312 is experiencing a thermal event 390, which increases the local temperature. For example, the area 331 of the shield layer 330 is heated due to the thermal event 390, and therefore may be at a higher temperature than the rest of the shield layer 330. When heat is transferred to the shield layer 330 and conducted through the entire shield layer 330, the temperature field near and inside the busbar stack 320 may be relatively less than the temperature field when the shield layer 330 is not present. For example, the area 322 of the busbar stack 320 may experience some temperature increase due to the thermal event 390.

[0037] However, the temperature rise of region 322 (e.g., compared to the rest of the busbar stack 320) may be reduced compared to a configuration without the shielding layer 330. In another example, region 322 may experience a lower temperature, a lower temperature rise, or both than region 331 of the shielding layer 330. Achieving a lower temperature, a lower temperature rise, or both of the laminated busbar 320 during operation may allow for a longer life, a reduced likelihood of failure, better operation, a more compact design, or a combination thereof. To illustrate, because the human factors and aspects of the thermal event 390 (e.g., hot gases, sparks, impinging gas jets, debris, irradiance) cannot directly affect the busbar stack 320, the busbar stack 320 is protected from the thermal event 390 and may operate as desired during the thermal event 390 (e.g., continue to operate, or for a sufficient time to allow shutdown or fault management).

[0038] In another example, the presence of the shielding layer 330 may block or otherwise reduce debris caused by the thermal event 390 from significantly affecting the busbar stack 320. For example, an explosion or other energetic aspect of the thermal event 390 may cause debris, dust, particles, plasma, embers, sparks, or other emissions to be ejected into surrounding portions of the battery system 300. In some such cases, the shielding layer 330 blocks the emissions from reaching the stacked busbars 320, slows the emissions before they reach the busbar stack 320, cools the emissions before they reach the busbar stack 320, or otherwise reduces the impact of the emissions on the busbar stack 320, as compared to a configuration without the shielding layer 330. For illustration, where the shielding layer 330 comprises steel grounded to the frame, the emissions from the thermal event may be cooled, extinguished, physically blocked, or otherwise suppressed rather than adversely affecting the busbar stack 320. Since the shielding layer 330 is not required to perform other functions, the degradation of the shielding layer 330 due to the thermal event 390 need not damage or otherwise jeopardize the operation of the battery system. For illustration, the shielding layer 330 is relatively consumable and is not used to make electrical connections in the battery system 300, but is used to protect the bus stack 320 from damage. In addition, since the shielding layer 330 can extend the time that the battery system 300 can operate during the thermal event 390 by reducing damage to the bus stack 320, the control system or diagnostic system may be able to identify the thermal event 390 and adjust the operation of the battery system 300 accordingly (e.g., reduce the current load, perform a controlled shutdown, perform an abrupt shutdown, activate active suppression measures, alert a user, alert a watchdog or other monitoring system, or a combination thereof).

[0039] Figure 4 A perspective view of an exemplary battery system 400 having a stacked busbar assembly 450 according to some embodiments of the present disclosure is shown. As shown, the battery system 400 includes a stacked busbar assembly 450, a battery module 410 (e.g., including a plurality of battery cells, battery cell 411 being one of the battery cells), a battery module 420 (e.g., including a plurality of battery cells, battery cell 421 being one of the battery cells), sidewalls 413 and 414, and a cover 412. The stacked busbar assembly 450 may include one or more current collectors, one or more busbars (e.g., separated by electrical insulating layers), one or more insulating layers, one or more shielding layers, any other suitable components, or any combination thereof. For example, the stacked busbar assembly 450 may include Figures 1 to 3 Any of a busbar assembly, a laminated busbar and a shielding layer.

[0040] The plurality of battery cells of each of the battery modules 410 and 420 may be arranged in a plane (e.g., in an array, pattern, or any other suitable arrangement) with subgroups of battery cells electrically coupled in parallel and subgroups electrically coupled in series. For example, the stacked busbar assembly 450 may include a busbar corresponding to the terminal voltage of the plurality of battery cells of the battery modules 410 and 420, and may also include a second busbar for forming a DC bus. In some embodiments (not shown), more than one stacked busbar assembly 450 may be included.

[0041] Figure 5 A top view of an exemplary battery system 500 having multiple battery modules according to some embodiments of the present disclosure is shown. As shown, the battery system 500 includes battery modules 503, 504, 505, 506, 507, 508, 509, 510, and 511 connected in series, a plurality of busbars (e.g., busbars 512 and 514, and a stacked busbar assembly 550), and a high-voltage power distribution system (e.g., area 502 includes a high-voltage power distribution system). The stacked busbar 550 is arranged on top of the battery module 503 (e.g., most of the battery module 503 is on the top). Figure 5 514). For illustration, in some embodiments, the potential across the most positively charged terminals in the plurality of battery modules and the most negatively charged terminals in the plurality of battery modules exceeds 300V. In some embodiments, the most positively charged terminals and the most negatively charged terminals of the battery may be electrically coupled to corresponding busbars (e.g., busbar 512 and / or busbar 514). For example, the battery system 500 may include a non-switched negative terminal busbar (e.g., busbar 512) and a non-switched positive terminal busbar (e.g., busbar 514). The non-switched negative terminal busbar and the non-switched positive terminal busbar may be components of a high voltage power distribution system (e.g., a high voltage power distribution system) described herein and shown in region 502 of the battery system 500.

[0042] Although the high-voltage power distribution system is depicted at area 502 on the far left of the battery system 500, the high-voltage power distribution system may be located in any position of the battery system 500 without departing from the scope of the present disclosure. In such embodiments, the location of the high-voltage power distribution system may be selected to minimize the risk of electrical short circuits (e.g., due to a collision of an electric vehicle or due to the non-switching length of the busbar). The high-voltage power distribution system may include one or more contactors, fuses, current sensors, voltage sensors, temperature sensors, switches, power electronics (e.g., IGBTs), electrical hardware, any other suitable components, or any combination thereof. The high-voltage power distribution system may be used to route the DC bus to one or more other systems (e.g., motor drives, motors, heaters, pumps, compressors). The busbar assembly 550 is arranged near area 502 and above the battery module 503 (e.g., and therefore arranged above the battery cells of the battery module 503). Therefore, the laminated busbar assembly 550 may include a shielding layer (e.g., a steel layer) to mitigate, prevent, or otherwise reduce the adverse effects of other failures associated with thermal events and battery cells. As shown, a shielding layer is disposed at the interface between the laminated bus bar assembly 550 and the battery module 503 (eg, with or without an air gap).

[0043] Figures 6 to 9 An exemplary laminated busbar assembly according to the present disclosure is shown. The laminated busbar assembly may include any suitable combination of Figures 6 to 9 For illustration purposes, Figures 6 to 9 The laminated busbar assembly may be included in a high voltage power distribution system of a battery system (eg, of an electric vehicle).

[0044] Figure 6 A cross-sectional side view of an exemplary laminated bus bar assembly 600 having layers according to some embodiments of the present disclosure is shown. As shown, the laminated bus bar assembly 600 includes layers 601, 602, 603, 604, and 605. Although the bus bar assembly is shown as having five layers, the bus bar assembly may include any suitable number of layers, components, or other suitable components having any suitable properties (e.g., electrical properties, mechanical properties, thermal properties).

[0045] In an illustrative example, layers 601 and 604 may include dielectric insulating layers, layer 603 may include a current collector, layer 602 may include a current collector electrically coupled to the current collector of layer 603 (e.g., a busbar or terminal busbar defining a DC bus), and layer 605 may include a shielding layer (e.g., a steel layer). In another illustrative example, layers 601 and 604 may include dielectric insulating layers, layer 602 may include a busbar electrically coupled to a battery cell subgroup, layer 604 may include an air gap (e.g., with or without a gap), and layer 605 may be a shielding layer (e.g., a steel layer).

[0046] Figure 7 A cross-sectional side view of an exemplary laminated busbar assembly 700 with more than one busbar according to some embodiments of the present disclosure is shown. As shown, the laminated busbar assembly 700 includes layers 701, 702, 703, 704, 705, and 706. As shown, layers 701, 703, and 705 include dielectric insulation layers, layers 702 and 704 include current collectors (e.g., busbars defining a DC bus), and layer 706 includes a shielding layer (e.g., a steel layer). For example, layers 702 and 704 may each include a copper busbar (or any other suitable material) that defines a DC bus of a battery system (e.g., for an electric vehicle). Therefore, layer 706 may be electrically insulated from layers 702 and 704 by layer 705, and layer 706 may provide shielding for events associated with a battery cell (e.g., arranged below layer 706, as shown).

[0047] Figure 8 A cross-sectional side view of an exemplary laminated busbar assembly 800 with more than one busbar according to some embodiments of the present disclosure is shown. As shown, the laminated busbar assembly 800 includes layers 801, 802, 803, 804, 805, and 806. As shown, layers 801, 802, and 805 include dielectric insulation layers, layers 803 and 804 include current collectors (e.g., busbars defining a DC bus), and layer 806 includes a shielding layer (e.g., a steel layer). For example, layers 803 and 804 may each include a copper busbar (or any other suitable material) that defines a DC bus of a battery system (e.g., for an electric vehicle). As shown, layers 803 and 804 need not be arranged in a stacked configuration, but may be partially or completely offset. Layer 806 is electrically insulated from layers 803 and 804 by layer 805, and layer 806 may provide shielding for events associated with battery cells (e.g., arranged below layer 806, as shown). In some embodiments, layer 802 need not be included (e.g., layers 803 and 804 may be in the same plane but separated by an air gap), or the layer need not extend as a complete layer to provide isolation between layers 803 and 804 (e.g., layer 802 may be included only in the space or vertical interface between layers 803 and 804).

[0048] Fig. 9A cross-sectional side view of another exemplary laminated busbar assembly 900 with more than one shielding member according to some embodiments of the present disclosure is shown. As shown, the laminated busbar assembly 900 includes layers 901, 902, 903, 904, 905, 906, and 907. As shown, layers 901, 903, and 905 include dielectric insulation layers, layers 902 and 904 include current collectors (e.g., busbars defining a DC bus), and layers 906 and 907 include shielding members (e.g., steel layers). For example, layers 902 and 904 may each include a copper busbar (or any other suitable material) that defines a DC bus of a battery system (e.g., for an electric vehicle). Layers 906 and 907 are electrically insulated from layers 902 and 904 by layer 905, and may provide shielding for events associated with battery cells (e.g., arranged below layers 906 and 907, as shown). The shielding layer may include a single layer, a non-continuous layer, one or more shields disposed between the remainder of the busbar assembly and the battery module or a plurality of battery cells thereof. For example, the busbar assembly may include shields along one or more portions to shield from particular battery cells (e.g., the shields may correspond to individual battery modules, and the gap between the illustrated layers 906 and 907 may be positioned above the gap between two adjacent battery modules disposed below the layer).

[0049] In the illustrative example, reference Figures 6 to 9 The electrically insulating layer may include any suitable electrically insulating material, such as rubber, plastic, powder coating, heat shrink, sensor, any other suitable dielectric material, or any combination thereof. Figures 6 to 9 , the conductive layer (e.g., electrically coupled to a plurality of electronic components) may include a metal, a metallic material (e.g., an alloy, a mixture, a solid solution), a plate, a sheet, a sensor, a wire, an insulating component other than a conductive component, any other suitable component, or any combination thereof. For illustration, in the context of an electric vehicle, Figures 6 to 9 The busbars in any conductive layer may be electrically coupled to switched 300V power lines associated with vehicle accessory components such as an air conditioning compressor. Figures 6 to 9 The busbars in any conductive layer of the battery can be electrically coupled to the non-switching terminals of the battery. For example, a portion of the busbar can be physically coupled to the terminals of the battery using any suitable physical and electrical coupling method.

[0050] In another example, a laminated busbar assembly may include: at least one busbar (e.g., made of copper, aluminum, or other conductive material) configured to be electrically coupled to a plurality of battery cells; at least one insulating layer disposed adjacent to the at least one busbar, wherein the at least one insulating layer is a dielectric; and a steel layer (e.g., which may be electrically grounded) disposed adjacent to the at least one insulating layer and disposed between the at least one busbar and the plurality of battery cells. The steel layer may be configured to shield the at least one busbar from thermal events associated with one or more of the plurality of battery cells. A portion of the steel layer of the laminated busbar assembly may be separated from the at least one insulating layer by an air gap. One or more gaps (e.g., made of a dielectric material) may extend through the air gap. For illustration, the at least one busbar may include a first busbar and a second busbar, and the at least one insulating layer may include: a first insulating layer disposed on a first side of the first busbar; a second insulating layer disposed on a second side of the first busbar opposite to the first side and between the first busbar and the first side of the second busbar; and a third insulating layer disposed on a second side of the second busbar opposite to the first side. The steel layer may be disposed adjacent to the third insulating layer. Such a configuration may include busbars and other components such as steel layers that are insulated from each other.

[0051] The foregoing is merely illustrative of the principles of the present disclosure, and various modifications may be made by those skilled in the art without departing from the scope of the present disclosure. The above embodiments are presented for purposes of illustration and not limitation. The present disclosure may also take many forms other than those explicitly described herein. Therefore, it should be emphasized that the present disclosure is not limited to the methods, systems, and devices explicitly disclosed, but is intended to include variations and modifications thereof, which are within the spirit of the following claims.

Claims

1. A laminated busbar assembly, comprising: at least one bus bar configured to be electrically coupled to a plurality of battery cells, each of the plurality of battery cells including a respective vent end; an insulating layer disposed adjacent to the at least one busbar, wherein the insulating layer is a dielectric; and a steel layer disposed adjacent to the insulating layer and between the at least one bus bar and each corresponding vent end of the plurality of battery cells, wherein the steel layer is configured to shield the at least one bus bar from ventilation of one or more of the plurality of battery cells, and wherein each corresponding vent end faces the steel layer. 2 . The laminated busbar assembly of claim 1 , wherein the at least one busbar comprises at least one of an aluminum material or a copper material. 3 . The laminated busbar assembly of claim 1 , wherein a portion of the steel layer is separated from the insulating layer by an air gap.

4. The laminated busbar assembly of claim 3, further comprising one or more gaps, wherein the one or more gaps comprise a dielectric material, and wherein the one or more gaps extend through the air gap.

5. The laminated bus bar assembly of claim 1, wherein the laminated bus bar assembly is configured to be installed as a single piece.

6. The laminated busbar assembly according to claim 1, wherein: The at least one busbar comprises a first busbar and a second busbar; The insulating layer is arranged between the second busbar and the steel layer; and The laminated busbar assembly also includes a second insulating layer disposed between the first busbar and the first side of the second busbar.

7. A battery system, comprising: a first plurality of battery cells arranged in a first battery module, wherein each of the first plurality of battery cells includes a respective vent end; a second plurality of battery cells, the second plurality of battery cells being arranged in a second battery module, wherein the first battery module and the second battery module are arranged adjacent to each other, and wherein the first battery module and the second battery module are electrically coupled in series; a stacked bus bar assembly arranged and configured to be electrically coupled to the first plurality of battery cells and the second plurality of battery cells, wherein the stacked bus bar assembly is arranged over a first portion of the first battery module that faces the respective vent end portions, and wherein the stacked bus bar assembly comprises: a first bus bar configured to be electrically coupled to the first plurality of battery cells and the second plurality of battery cells, a second bus bar configured to be electrically coupled to the first plurality of battery cells and the second plurality of battery cells, a first insulating layer, the first insulating layer being arranged between the first busbar and the second busbar, a second insulating layer, the second insulating layer being disposed adjacent to the second busbar, and A steel layer is disposed adjacent to the second layer and between the second bus bar and the plurality of battery cells, wherein the steel layer is configured to shield the first bus bar and the second bus bar from venting of one or more battery cells in the first plurality of battery cells.

8. The battery system according to claim 7, wherein the first bus bar comprises at least one of an aluminum material or a copper material, and wherein the second bus bar comprises at least one of an aluminum material or a copper material.

9. The battery system of claim 7, wherein a portion of the steel layer is separated from the second insulating layer by an air gap.

10. The battery system of claim 9, further comprising one or more gaps, wherein the one or more gaps comprise a dielectric material, and wherein the one or more gaps extend through the air gap.

11. The battery system of claim 7, wherein the steel layer is configured to be electrically grounded. 12 . The battery system according to claim 7 , further comprising a third insulating layer disposed adjacent to the first bus bar and opposite to the first insulating layer.

13. The battery system of claim 7, wherein the laminated bus bar assembly is installed in the battery system as a single workpiece.

14. A battery system, comprising: a plurality of battery modules, each of the plurality of battery modules comprising a corresponding plurality of battery cells, wherein the battery modules are electrically coupled via a plurality of bus bars, and wherein a first of the plurality of battery cells each comprises a corresponding vent end; a stacked busbar assembly comprising at least one busbar of the plurality of busbars, wherein the stacked busbar assembly is configured to be electrically coupled to the first plurality of battery cells and the second plurality of battery cells, wherein the at least one busbar is arranged over a first portion of a first battery module, and wherein the stacked busbar assembly further comprises: an insulating layer disposed adjacent to the at least one busbar, and A steel layer is disposed adjacent to the at least one insulating layer and between the at least one bus bar and the plurality of battery cells, wherein the steel layer is configured to shield the at least one bus bar from ventilation with one or more of the plurality of battery modules.

15. The battery system of claim 14, wherein the at least one bus bar comprises at least one of an aluminum material or a copper material.

16. The battery system of claim 14, wherein a portion of the steel layer is separated from the insulating layer by an air gap.

17. The battery system of claim 16, further comprising one or more gaps, wherein the one or more gaps comprise a dielectric material, and wherein the one or more gaps extend through the air gap.

18. The battery system of claim 14, wherein the steel layer is configured to be electrically grounded. 19 . The battery system according to claim 14 , wherein the insulating layer is a first insulating layer, the battery system further comprising a second insulating layer disposed adjacent to the at least one bus bar and opposite to the first insulating layer.

20. The battery system of claim 14, wherein the laminated bus bar assembly is installed in the battery system as a single piece.

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