Traction Battery Bus Bar Nesting in Notched Cross-Member Beams

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Solution Overview

Problem

Existing bus bar routing configurations in traction battery packs often increase the vertical footprint and compromise the structural integrity of the battery pack, necessitating a more efficient and space-saving design.

Innovation Solution

The implementation of notched cross-member beams that accommodate bus bars over the top of cell stacks, utilizing reinforcement sections to support the bus bars and maintain structural integrity without increasing the vertical footprint.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If bus bars are routed over the top of cell stacks using conventional configurations, then electrical connections are established, but the vertical footprint of the battery pack increases

Engineering Contradiction:

Improvevertical footprintVSAvoidbus bar routing convenience

Core Design Contradiction:

Volume of moving objectVSEase of operation

Solution Approach 1:

The bus bar is nested within a notch formed in the cross-member beam, allowing the bus bar to be accommodated within the structural framework of the battery pack rather than extending externally. This nesting approach reduces the vertical footprint while maintaining electrical connectivity.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

Instead of routing the bus bar horizontally over the cell stacks, the design transitions to a vertical arrangement where the bus bar is positioned within the notch of the cross-member beam, utilizing the vertical dimension of the beam structure to accommodate the electrical connection.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Volume of moving object

If bus bars are positioned within notched cross-member beams, then the vertical footprint is reduced, but the structural integrity of the cross-member beams may be compromised

Engineering Contradiction:

Improvevertical footprintVSAvoidstructural integrity of cross-member beams

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

Reinforcement sections are added to specific locations within the cross-member beam structure, particularly at the notch areas where bus bars are positioned. This local reinforcement maintains the overall structural integrity while allowing the notch configuration to reduce vertical footprint.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The cross-member beam is constructed as a composite structure incorporating reinforcement sections that combine different materials or structural elements. This composite design allows the beam to maintain strength while accommodating the notched configuration for bus bar routing.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS12565092B2Bus bar routing configurations for traction battery packs

Publication Date: 2026.03.03 FORD GLOBAL TECH LLC

AI summary

Bus bar routing configurations are provided for traction battery packs. Exemplary routing configurations may position the bus bar over top of one or more cells stacks of the traction battery pack. A structural cross-member beam of each cell stack may include a notch for accommodating the bus bar. The bus bar may therefore be conveniently nested within the cross-member beam without increasing the vertical or “z-axis” footprint of the traction battery pack.