Battery pack busbar protection

Abstract

The present disclosure provides a battery pack comprising a plurality of battery arrays, each battery array having a top cover and at least one busbar connected between the battery arrays. Each busbar is connected between a first battery array and a second battery array and is positioned such that each busbar substantially covers at least a portion of each of the top covers of the first battery array and the second battery array. A layer of silicate material is disposed between each busbar and each top cover, each layer of silicate material is shaped to follow a shape of the respective busbar such that the each layer of silicate material is located between the respective busbar and the respective top cover, each layer of silicate material covers at least a surface of the respective busbar facing the respective top cover, and a surface of each respective busbar facing away from the respective top cover is not covered by a layer of silicate material.

Description

Technical Field

[0001] This disclosure relates to battery packs for electric vehicles, and more specifically, to a protection system for busbars in a battery pack to minimize heat propagation. Background Technology

[0002] Battery packs for electric vehicles typically comprise multiple battery cells arranged in an array or module. These battery cells are electrically connected by conductive elements called busbars, which carry high currents between the battery cells and the module. Busbars are typically made of highly conductive metals such as copper or aluminum and are positioned above the battery array to make connections between terminals.

[0003] In traditional battery pack designs, such as those implemented in vehicles, the busbar is typically positioned above the battery array. This positioning allows for efficient electrical connection but can present challenges in certain situations. During normal operation, battery cells generate heat that must be managed to maintain optimal performance and lifespan. However, managing any temperature rise that may occur outside of normal operating conditions is also expected. In some approaches, busbar designs often rely on polymer-based insulating coatings to provide electrical isolation. Summary of the Invention

[0004] The present invention is provided to introduce the selected concepts in a simplified form, which will be further described in the following detailed description.

[0005] In a first aspect, a battery pack is provided. The battery pack includes a plurality of battery arrays, each battery array having a top cover and at least one busbar connected between the battery arrays, such that: each busbar is connected between a first battery array and a second battery array, and is positioned such that each busbar substantially covers at least a portion of the top cover of each of the first and second battery arrays; a silicate material layer is disposed between each busbar and each top cover, wherein: each busbar is shaped to connect between terminals of the first and second battery arrays; each silicate material layer is shaped to conform to the shape of the respective busbar, such that each silicate material layer is located between the respective busbar and the respective top cover; each silicate material layer at least covers the surface of the respective busbar facing the respective top cover; and the surface of each respective busbar facing away from the respective top cover is not covered by the silicate material layer or silicate sheet.

[0006] This construction provides thermal protection for the busbars by shielding them during battery cell venting events. The silicate material layer acts as a barrier.

[0007] The silicate material layer can be formed from mica.

[0008] Using mica as a silicate material provides excellent thermal insulation and electrical resistance properties, which further enhances the protection capabilities of the battery pack design.

[0009] The silicate material layer can essentially surround the corresponding busbar.

[0010] Surrounding the busbar with silicate material provides comprehensive protection from multiple directions, which reduces vulnerability to thermal events and potential short circuits.

[0011] Each busbar may have a sidewall, and each silicate material layer may cover at least one sidewall of the corresponding busbar.

[0012] Covering at least one sidewall of the busbar with silicate material provides additional protection against lateral heat transfer and potential short circuits due to debris buildup.

[0013] Alternatively, each silicate material layer may cover only one sidewall of the corresponding busbar.

[0014] This construction provides targeted protection while potentially reducing material usage and weight.

[0015] In some embodiments, each silicate material layer may cover both sidewalls of the corresponding busbar.

[0016] Covering both sidewalls provides maximum protection against thermal events and short circuits from multiple directions.

[0017] The silicate material layer can have a roughly U-shaped cross-section.

[0018] The U-shaped cross-section allows silicate material to effectively surround the busbar to provide protection on multiple surfaces while maintaining a compact design.

[0019] Optionally, each silicate material layer may have a cross-section comprising a base and two substantially parallel sidewalls, the sidewalls being substantially perpendicular to the base and extending away from the base.

[0020] This design creates a protective channel for the busbar to provide comprehensive protection, while potentially simplifying manufacturing and assembly processes.

[0021] Each silicate material layer can be fixed to the corresponding busbar.

[0022] Attaching the silicate material layer to the busbar ensures consistent positioning and protection, even during vehicle operation or in the event of mechanical impact.

[0023] Optionally, each silicate material layer may be spaced apart from the corresponding busbar to create an air gap between the silicate material layer and the corresponding busbar.

[0024] Air gaps can provide additional thermal insulation and allow for thermal expansion of components, thereby potentially reducing stress on the assembly.

[0025] Each busbar can be shaped to accommodate an additional portion on the corresponding top cover, and the corresponding silicate material layer can be shaped to follow the shape of the busbar and located between the additional portion on the corresponding top cover and the corresponding busbar.

[0026] This feature allows for integration with existing battery array designs while maintaining the protective benefits of the silicate material layer.

[0027] Each busbar may be coated with flame-retardant material.

[0028] Adding a flame-retardant coating to the busbar can provide an additional layer of protection against thermal events.

[0029] Flame-retardant materials can be flame-retardant polymers.

[0030] The use of flame-retardant polymer coatings provides effective protection while potentially being easier to apply than other flame-retardant materials.

[0031] Each silicate material layer can be molded.

[0032] Molded silicate materials allow for precise shaping to match the busbar profile, thus ensuring optimal coverage and protection.

[0033] Alternatively, each silicate material layer may be machined.

[0034] Machining silicate materials offers the flexibility to produce complex shapes and allows for precise tolerances in the protective layer.

[0035] The vehicle may include a battery pack as described in any of the foregoing aspects. Attached Figure Description

[0036] Non-restrictive and non-exhaustive examples are described with reference to the following figures.

[0037] Figure 1A A portion of a busbar containing busbar protection as described herein is shown;

[0038] Figure 1B A portion of a battery pack including busbar protection as described herein is shown;

[0039] Figure 2 Another portion of the battery pack, including busbar protection as described herein, is shown;

[0040] Figure 3 A portion of a busbar including busbar protection as described herein is shown;

[0041] Figure 4Another portion of the busbar, including busbar protection as described herein, is shown;

[0042] Figure 5 A side view is shown of a portion of a busbar including busbar protection as described herein;

[0043] Figures 6A to 6E A combination of busbar and busbar protection device as described herein is shown;

[0044] Figure 7A Another portion of the busbar, including busbar protection as described herein, is shown;

[0045] Figure 7B A portion of a battery pack, including busbar protection as described herein, is shown; and

[0046] Figure 8 A vehicle containing a battery pack including busbar protection as described herein is shown.

[0047] Common reference numerals are used in all the accompanying drawings to indicate similar features. Detailed Implementation

[0048] This disclosure relates to battery packs for use in vehicles and other applications.

[0049] Battery packs typically consist of multiple arrays of cells connected by conductive elements such as busbars. These busbars are used to electrically connect the cell arrays and allow current to flow between them. However, in some cases, positioning the busbars close to the cell array components can be challenging.

[0050] This disclosure provides a battery pack with enhanced protection for the busbars. This protection is designed to mitigate potential problems that may arise during battery operation, particularly under high temperature or fault conditions.

[0051] The protective elements described in this article can be implemented in various configurations to suit different battery pack designs and requirements. These elements are used to insulate and protect the busbars from direct contact with battery array components.

[0052] Battery packs that include the disclosed busbar protection are suitable for use in vehicles such as electric vehicles or hybrid electric vehicles.

[0053] A battery pack comprises multiple battery arrays. Each battery array includes multiple battery cells arranged in a specific configuration. The battery arrays are designed to provide the desired voltage and capacity for the battery pack.

[0054] Figure 1A A portion of the busbar 120, protected by a silicate material layer 110, is shown. This is in Figure 1BA more detailed description is provided below.

[0055] The battery pack 100 includes a plurality of battery arrays arranged within a portion of the battery pack 100. Figure 1B A cross-sectional view showing key components of the battery pack 100 is shown. A portion of the first battery array 130A and a portion of the second battery array 130B are separated by a wall 150 between the arrays. Each battery array includes a battery array top cover 140 located above the corresponding array portion.

[0056] Busbar 120 extends between the battery arrays and electrically connects the battery arrays. Busbar 120 is positioned such that it substantially covers at least a portion of the top cover 140 of the battery arrays, including both the first battery array 130A and the second battery array 130B. Busbar 120 includes terminals 125 for electrical connection.

[0057] A silicate material layer 110 is disposed between the busbar 120 and the battery array top cover 140. The silicate material layer 110 is shaped to follow the contour of the busbar 120, thereby creating a protective barrier between the busbar 120 and the components below.

[0058] Busbar 120 is specifically shaped to connect the terminals of the first battery array 130A and the terminals of the second battery array 130B to facilitate electrical connection between the arrays while maintaining proper spacing from other components. This arrangement allows for effective electrical connection within the battery pack while incorporating protective measures.

[0059] Figure 2 A cross-sectional view of a portion of the battery pack 200 is shown. This portion of the battery pack 200 includes a portion of the array 230 located below the battery array top cover 140. A busbar 120 extends across the battery array top cover 140 and connects to terminals 125.

[0060] A silicate material layer 110 is located between the busbar 120 and the top cover 140 of the battery array. The silicate material layer 110 is shaped to follow the contour of the busbar 120 to create a protective barrier between the busbar 120 and the components below. This configuration provides insulation and protection for the busbar 120 during battery cell venting events.

[0061] Figure 3 A perspective view of the arrangement of the silicate material layer 110 and the busbar 120 is shown. The silicate material layer 110 forms a channel-like or groove-like structure that closely follows the shape of the busbar 120. The busbar 120 is designed to be located within the channel formed by the silicate material layer 110.

[0062] A silicate material layer 110 covers the surface of the busbar 120 facing the battery array top cover 140. However, the surface of the busbar 120 facing away from the battery array top cover 140 is not covered by the silicate material layer 110. This arrangement allows for the necessary electrical connections while providing protection for the busbar 120.

[0063] Each battery array includes a top cover. The top cover has multiple functions, including protecting the internal components of the battery array, providing structural support, and facilitating connections between arrays. The top cover can be made of various materials, such as plastics, metals, or composite materials, selected based on factors such as durability, thermal performance, and manufacturability.

[0064] The battery arrays are arranged within the battery pack, allowing busbars to connect adjacent arrays. These busbars are positioned to cover at least a portion of the top cover of the connected battery arrays. This arrangement allows for efficient electrical connection while maintaining a compact overall design.

[0065] In some examples, the top cover of the battery array may include additional portions or features to accommodate the shape or positioning of the busbars. This additional portion may be a protrusion, a recess, or other structural element designed to engage with the busbars. In this case, a layer of silicate material may be placed between this additional portion of the top cover and the busbars. This silicate material provides insulation and protection.

[0066] The construction of the battery array, top cover, and busbars allows for efficient encapsulation of the battery pack while providing necessary electrical connections and protection. This design approach is applicable to a variety of battery pack sizes and layouts to suit different vehicle or application requirements.

[0067] The battery pack includes busbars for electrically connecting the battery arrays. These busbars are shaped to connect the terminals of different battery arrays, thereby allowing current to flow between the arrays. The specific shape of each busbar can vary depending on the layout and construction of the battery arrays it is connected to.

[0068] Busbars can be constructed from highly conductive materials such as copper or aluminum to minimize resistance. The cross-sectional area of ​​the busbar can be designed to accommodate the expected current while managing heat generation.

[0069] In some examples, the busbar may have a flat, elongated shape that spans between the terminals of adjacent battery arrays. In other examples, the busbar may have a more complex three-dimensional shape to define routes or optimize current paths around other components within the battery pack.

[0070] Careful consideration should be given to the positioning of the busbar within the battery pack to ensure proper electrical connections while maintaining battery pack efficiency. The busbar can be positioned as part of a top cover covering multiple battery arrays, allowing for compact packaging of battery pack components.

[0071] Busbars may be coated with a protective material. In some examples, busbars are coated with an engineering thermoplastic (SABIC). This coating provides the busbar with electrical insulation, corrosion resistance, and thermal management.

[0072] The connection points between the busbar and the battery array terminals may include features that ensure safe and reliable electrical contact. These features may include threaded connections, press-fit fittings, or welded joints, depending on the specific design requirements of the battery pack.

[0073] In some configurations, multiple busbars can be used in parallel to increase current carrying capacity or provide redundancy in the electrical connections between battery arrays. The arrangement of these parallel busbars can be optimized for factors such as current distribution, thermal management, and overall battery pack size.

[0074] The battery pack includes a layer of silicate material located between each busbar and the top cover of the battery array. This silicate material serves as a protective layer, providing insulation and protection for the busbars.

[0075] In some examples, silicate materials include mica, a naturally occurring mineral known for its excellent electrical insulation and heat resistance. Mica is well-suited for this application due to its ability to withstand high temperatures and maintain its insulating properties under extreme conditions.

[0076] The silicate material layer is shaped to conform to the contour of the busbar it protects. This shaping ensures that the silicate material covers the top surface of the busbar facing the battery array. By conforming to the shape of the busbar, the silicate material layer provides full protection along the length of the busbar.

[0077] Figure 4 and Figure 5 An orthogonal view of the busbar assembly is provided, further illustrating the relationship between the silicate material layer 110 and the busbar 120. Figure 4 A top view is shown of the busbar 120, battery terminals 125, and silicate material layer 110, wherein the silicate material layer 110 is located between the busbar 120 and the top cover of the battery array. Figure 4 In the middle, the silicate material layer 110 extends beyond either side of the battery terminal 125, but does not substantially surround the battery terminal 125. Figure 5 A cross-sectional view of the busbar arrangement is shown, wherein the busbar 120 is shaped to extend over a portion of the battery pack, i.e., the busbar 120 includes a protruding portion. (See also...) Figure 5 As can be seen, the shape of the silicate material layer 110 generally follows the shape of the busbar 120. These figures illustrate how the silicate material layer 110 extends along the length of the busbar 120, thereby creating a protective barrier between the busbar 120 and other components.

[0078] The silicate material layer 110 has multiple protective functions. The silicate material layer 110 protects the busbar 120 during thermal events. Additionally, the silicate material layer 110 prevents short circuits between the busbar 120 and other components by providing an insulating barrier.

[0079] In some configurations, the silicate material layer 110 may be shaped to form a “bridge” on the power distribution system (EDS) components. This allows for the integration of necessary electrical components while maintaining the protective function of the silicate material layer 110.

[0080] Various configurations of the silicate material layer can be achieved to accommodate different busbar designs and protection requirements. In some examples, the silicate material essentially surrounds the busbar to provide protection on multiple sides. This configuration can take the form of a U-shaped cross-section, where the silicate material covers the bottom and sides of the busbar.

[0081] Alternatively, the silicate material can be shaped to cover at least one sidewall of the busbar in addition to the surface facing the top cover. This L-shaped configuration is particularly useful when one side of the busbar needs protection, such as when the busbar is positioned at the edge of the battery array.

[0082] For applications requiring minimal material usage, a flat construction can be employed. In this case, silicate material covers only the surface of the top cover of the busbar facing the battery array. This flat design still provides critical protection against potential short circuits or thermal events originating from the battery array below.

[0083] The silicate material layer 110 and busbar 120 can be arranged in various configurations to provide optimal protection and insulation within the battery pack. Figures 6A to 6C Cross-sectional views of different arrangements of silicate material layer 110 relative to busbar 120 are shown.

[0084] Figure 6A A U-shaped configuration is shown, in which a silicate material layer 110 substantially surrounds the busbar 120. The silicate material layer 110 includes a base extending below the busbar 120 and an upwardly extending side covering the lateral sides of the busbar 120. In some examples, the silicate material layer 110 may be continuously curved, such that the silicate material layer does not have sharp edges. This arrangement can provide comprehensive protection for the busbar 120 by protecting it from multiple directions.

[0085] Figure 6B An optional U-shaped structure of silicate material layer 110 is depicted, which employs a higher density than... Figure 6A The shape shown is more square. In this arrangement, the silicate material layer 110 includes a base located below the busbar 120 and an upwardly extending portion covering the sides of the busbar 120 (similar to...). Figure 6AAs shown in the diagram. This U-shaped structure, with its flat sides and flat base, is similar to... Figure 6A As shown, comprehensive protection can be provided by protecting the busbar 120 from multiple directions.

[0086] Figure 6C The L-shaped structure of the silicate material layer 110 is shown, which resembles a side portion that has been removed. Figure 6B The configuration shown is as follows. This arrangement provides protection for the lower part and one side of the busbar 120 by protecting the base and sides of the busbar 120. Figure 6C The side of the busbar 120 protected by the silicate material layer 110 can be on either side of the busbar 120.

[0087] Figure 6D and Figure 6E A side view of the optional construction is presented. Figure 6D A silicate material layer 110 is shown that is flat and “riverbed” shaped relative to the busbar 120, which protects the underside of the busbar 120. Figure 6E The silicate material layer 110 shown substantially surrounds the busbar 120 and protects all sides of the busbar 120.

[0088] In some examples, the silicate material layer 110 may be secured to the busbar 120 to ensure consistent positioning and protection. Alternatively, the silicate material layer 110 may be spaced apart from the busbar 120 to create an air gap between the silicate material layer 110 and the busbar 120. This air gap provides additional insulation and allows for thermal expansion.

[0089] Busbar 120 and silicate material layer 110 can be shaped to fit an additional portion on battery array top cover 140. In this case, silicate material layer 110 follows the shape of busbar 120 and is located between the additional portion on battery array top cover 140 and busbar 120.

[0090] The silicate material layer 110 may be formed from mica, which provides excellent electrical insulation and heat resistance. The silicate material layer 110 can be manufactured using various processes. In some examples, the silicate material layer 110 is molded to achieve a desired shape and configuration. Alternatively, the silicate material layer 110 may be machined to precise specifications, allowing for customized shapes and sizes to fit a specific busbar 120 design.

[0091] These various constructions and manufacturing methods of the silicate material layer 110 provide flexibility in designing the protective arrangement of the busbars 120 within the battery pack.

[0092] Figure 7A It shows the relationship with Figure 4 The arrangement shown is similar to that of the one illustrated. Figure 7A The image shows a busbar 120, battery terminals 125, and a silicate material layer 110, wherein the silicate material layer 110 is located between the busbar 120 and the top cover of the battery array. Figure 4 The silicate material layer 110 shown is different; it extends beyond either side of the battery terminal 125 and is shaped to substantially surround the battery terminal 125. The silicate material layer 110 includes a flap portion 750 extending beyond the battery terminal 125. Figure 7A The silicate material layer 110 shown includes fold lines 755 to enable the silicate material layer 110 to be folded.

[0093] Figure 7B A portion of a battery array 200, including a busbar 120, battery terminals 125, and a silicate material layer 110, is shown, with the silicate material layer 110 positioned between the busbar 120 and the top cover of the battery array 200. (As can be seen...) Figure 7B As can be seen, the silicate material layer 110 is folded relative to the fold line 755, allowing the silicate material layer to align with and protect the end walls 220 of the battery array 220. The tab portion 750 can be folded around the edge of the battery array 200 to extend downwards around the side of the array 200 and cover any plastic-overmolded battery terminals 125. This helps reduce gas escaping from the battery terminals 125. It also provides protection for the battery terminals 125. This protection can also extend to adjacent or neighboring arrays 200 within the battery pack.

[0094] The tab 750 may be flush with the battery terminal 125, or positioned to have a sufficient gap with the battery terminal 125 to allow fluid to flow out freely.

[0095] In some examples, a silicate material layer may be used to encapsulate the battery terminal 125, for example, to create a box around the battery terminal 125 and any overmolded plastic thereon.

[0096] Silicate material layers can be manufactured using various methods. In some examples, the silicate material is molded to achieve a desired shape. Molding allows for precise control over the size and profile of the protective layer, ensuring a tight fit and optimal coverage with the busbar.

[0097] Optionally, the silicate material can be machined to create a protective layer. Machining can be advantageous when producing complex shapes or when small-batch production is required. This method allows for fine-tuning of the silicate material to accommodate changes in busbar design or battery pack layout.

[0098] The thickness of the silicate material layer can be selected based on factors such as expected thermal conditions, electrical insulation requirements, and space constraints within the battery pack. The thickness can be uniform across the entire protective layer or varied in different regions to provide enhanced protection in critical areas.

[0099] In some configurations, the silicate layer can be directly attached to the busbar to create an integrated protection unit. In other examples, the silicate layer can be installed as a separate component if needed, allowing for easier replacement or maintenance of the protection layer.

[0100] In addition to the silicate material layer, the battery pack may also include other protective features. One such feature could be the application of a flame-retardant coating on the busbars.

[0101] Flame-retardant materials can be applied to coat the busbars. This flame-retardant material provides an extra layer of protection against thermal events and helps prevent the spread of fire within the battery pack.

[0102] In some examples, the flame-retardant material is a flame-retardant polymer. Flame-retardant polymers are materials designed to prevent ignition and slow the spread of flames. These polymers may contain additives or have inherent properties that make them resistant to combustion.

[0103] Various methods can be used to apply flame-retardant polymer coatings to busbars. In some examples, the coating can be applied by dip coating, in which the busbar is immersed in a liquid polymer solution and then removed to allow the coating to cure. Alternatively, a spraying technique can be used to apply a uniform flame-retardant polymer layer to the surface of the busbar.

[0104] The thickness of the flame-retardant polymer coating can be selected based on factors such as the desired level of protection, thermal management requirements, and space constraints within the battery pack. The coating thickness can be uniform across the entire busbar or varied in different areas to provide enhanced protection in critical areas.

[0105] The flame-retardant polymer coating works in conjunction with the silicate material layer to create a comprehensive protection system for the busbar. While the silicate material layer provides insulation and protection between the busbar and the battery array components, the flame-retardant coating offers additional resistance to thermal events and helps prevent the busbar from becoming a source of fire spread.

[0106] A silicate material layer, including mica, can be used as a protective barrier between the busbar and the top cover of the battery array. This arrangement helps to insulate the busbar from direct contact with the battery array components.

[0107] In some examples, the silicate material layer is directly attached to the busbar. This construction creates an integrated protection unit that moves with the busbar to ensure consistent coverage and protection. The attached silicate material layer also helps to dissipate heat more effectively from the busbar.

[0108] Optionally, the silicate material layer may be spaced apart from the busbar to create an air gap between the two components. This air gap provides additional insulation and allows some thermal expansion of the busbar without damaging the protective layer. The gap also facilitates easier inspection or replacement of components if needed.

[0109] Silicate material layers and busbars are arranged in various configurations to provide thermal and electrical insulation. In some examples, the silicate material layers essentially surround the busbar to create protective barriers on multiple sides. This arrangement enhances the overall insulation and protection of the busbar against potential thermal events or debris.

[0110] In some configurations, the silicate material layer covers only one sidewall of the busbar. This asymmetrical arrangement is suitable for situations where the busbar is primarily exposed from one direction, while allowing for more efficient encapsulation in other areas.

[0111] In some implementations, the silicate material layer may have a U-shaped cross-section. This U-shaped structure allows the silicate material layer to cover the bottom surface of the busbar and both sidewalls to provide full protection, while making the top surface of the busbar available for electrical connection.

[0112] In various examples, a layer of silicate material covers at least one sidewall of the busbar. This construction ensures that the busbar is protected.

[0113] One feature of this arrangement is that a layer of silicate material covers both sidewalls of the busbar. This double sidewall coverage maximizes lateral protection for the busbar.

[0114] In some implementations, the silicate material layer has a cross-section with a base and vertical sidewalls. This geometry establishes a channel-like structure surrounding the busbar, thus providing a stable and protective enclosure. The base provides insulation from what lies beneath, while the vertical sidewalls protect the lateral surfaces of the busbar.

[0115] These various configurations of the silicate material layer relative to the busbar allow for adaptive protection strategies within the battery pack to accommodate different design requirements.

[0116] During thermal events, such as battery cell venting within a battery array, the silicate layer acts as a protective element for the busbars. The heat-resistant properties of silicate materials help maintain their structural integrity and insulation capabilities even under high-temperature conditions.

[0117] The interaction between the silicate layer and the top cover of the battery array can help manage potential thermal accidents. If the battery cells within the array experience a thermal runaway event, the top cover may be subjected to high temperatures and high pressures.

[0118] In some cases, a silicate layer can provide additional cushioning between the busbar and other components. This cushioning effect helps prevent direct contact between the busbar and other conductive elements.

[0119] Figure 8 The battery pack 250 is shown integrated into the body 800. Positioned within the lower part of the body 800, the battery pack 250 demonstrates how a battery system can be incorporated into a vehicle design.

[0120] Placing the battery pack 250 in the lower part of the body 800 offers several advantages for vehicle design and performance. Positioning the battery pack 250 at a lower position within the body 800 contributes to a lower center of gravity, which enhances stability and handling characteristics.

[0121] Integrating the battery pack 250 into the body 800 involves considerations of structural support and protection. The body 800 can be designed to accommodate the weight and size of the battery pack 250, thereby ensuring proper load distribution and structural integrity.

[0122] The busbars within the battery pack 250 may be coated with a flame-retardant material, which may be a flame-retardant polymer. This coating provides an additional layer of protection for the electrical components within the battery pack 250.

[0123] Integrating the battery pack 250 into the body 800 also involves considerations of thermal management. The body 800 can be designed to facilitate proper cooling and ventilation of the battery pack 250, which can be important for maintaining optimal battery performance and lifespan.

[0124] In some examples, the vehicle body 800 may be designed to allow for the maintainability of the battery pack 250. This may include access points or removable sections that facilitate maintenance or replacement of battery components without requiring extensive disassembly of the vehicle.

[0125] Integrating the battery pack 250 into the vehicle body 800 demonstrates how to apply the protective measures described for battery pack components, such as silicate material layers and busbar arrangements, in a real automotive environment.

[0126] The effectiveness of mica protection during thermal propagation testing has been noted. Battery packs incorporating the described protection measures have demonstrated enhanced resistance to the spread of thermal events between battery arrays during thermal propagation testing.

[0127] The combination of these protective elements (busbars, silicate layers, and top caps) creates a system designed to suppress and mitigate the effects of potential thermal events within the battery pack.

[0128] Features of any of the examples or embodiments outlined above may be combined to produce additional examples or embodiments without losing the intended effect. It should be understood that the descriptions of the embodiments or examples provided above are merely exemplary, and various modifications can be made by those skilled in the art. Furthermore, those skilled in the art will recognize that many further modifications and combinations of the aspects are possible. Therefore, the described aspects are intended to cover all such changes, modifications, and variations falling within the scope of the appended claims.

Claims

1. A battery pack comprising a plurality of battery arrays, each battery array having a top cover and at least one busbar connected between the battery arrays, such that: Each busbar is connected between the first battery array and the second battery array and is positioned such that each busbar substantially covers at least a portion of the top cover of each of the first battery array and the second battery array. A silicate material layer is provided between each busbar and each top cover, wherein: Each busbar is shaped to connect between the terminals of the first battery array and the terminals of the second battery array; Each silicate material layer is shaped to conform to the shape of the corresponding busbar, such that each silicate material layer is located between the corresponding busbar and the corresponding top cover; Each silicate material layer at least covers the surface of the corresponding busbar facing the corresponding top cover; and The surface of each corresponding busbar that faces away from the corresponding top cover is not covered by a silicate material layer.

2. The battery pack according to claim 1, wherein, Each silicate material layer is formed from mica.

3. The battery pack according to any one of the preceding claims, wherein, Each silicate material layer essentially surrounds the corresponding busbar.

4. The battery pack according to claim 1 or claim 2, wherein, Each busbar has a sidewall, and each silicate material layer covers at least one sidewall of the corresponding busbar.

5. The battery pack according to claim 1 or claim 2, wherein, Each busbar has a sidewall, and each silicate material layer covers only one sidewall of the corresponding busbar.

6. The battery pack according to claim 4, wherein, Each silicate material layer covers the two sidewalls of the corresponding busbar.

7. The battery pack according to claim 6, wherein, Each silicate material layer has a roughly U-shaped cross-section.

8. The battery pack according to claim 6, wherein, Each silicate material layer has a cross-section comprising a base and two substantially parallel sidewalls that are substantially perpendicular to the base and extend away from it.

9. The battery pack according to any one of the preceding claims, wherein, Each silicate material layer is fixed to the corresponding busbar.

10. The battery pack according to any one of claims 1 to 7, wherein, Each silicate material layer is spaced apart from the corresponding busbar to create an air gap between the silicate material layer and the corresponding busbar.

11. The battery pack according to any one of the preceding claims, wherein, Each busbar is shaped to fit an additional portion on the corresponding top cover, and a corresponding silicate material layer is shaped to follow the shape of the busbar and is located between the additional portion on the corresponding top cover and the corresponding busbar.

12. The battery pack according to any one of the preceding claims, wherein, Each busbar is coated with flame-retardant material.

13. The battery pack according to claim 12, wherein, The flame-retardant material is a flame-retardant polymer.

14. The battery pack according to any one of the preceding claims, wherein, Each silicate material layer is molded.

15. The battery pack according to any one of claims 1 to 13, wherein, Each silicate material layer is machined.

16. A vehicle comprising a battery pack according to any one of claims 1 to 15.

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