Integrated Battery Interconnect Assembly for Compact Cell Connection
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Solution Overview
Problem
Existing traction battery packs for electrified vehicles face challenges in efficiently and compactly connecting multiple battery cells, which can lead to increased complexity and parts count.
Innovation Solution
The integration of a battery interconnect assembly within the battery array, featuring a cell sensing assembly, top cover, and pivotably connected bus bar modules, allows for efficient electrical connection of battery cells while enabling configuration between assembly and shipping positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate interconnect assemblies are used for each battery cell connection, then reliable electrical connection is achieved, but parts count and assembly complexity increase
Solution Approach 1:
The patent combines multiple separate interconnect assemblies into a single integrated battery interconnect assembly that electrically connects multiple battery cells simultaneously. The integrated assembly includes a unified housing with multiple bus bar modules arranged in arrays, eliminating the need for multiple separate interconnect components and reducing overall assembly complexity while maintaining reliable electrical connections across all battery cells.
2Stability of the object's composition
If bus bar modules are fixed in position, then structural stability is achieved, but ease of assembly and shipping is reduced
Solution Approach 1:
The patent incorporates hinge assemblies that enable the bus bar modules to pivot between a first position during assembly and a second position during operation. This dynamic configuration allows the bus bar modules to be easily maneuvered into place during assembly while maintaining stable structural connections once positioned, thereby achieving both ease of assembly and structural stability.
3Adaptability or versatility
If multiple separate components are used for battery interconnection, then functional versatility is achieved, but manufacturing efficiency decreases
Solution Approach 1:
The patent integrates multiple functional components including bus bar modules, hinge assemblies, and sensing assemblies into a single manufactured unit. This integration allows the entire battery interconnect assembly to be produced as one component rather than assembling multiple separate parts, significantly improving manufacturing efficiency while maintaining all necessary functional capabilities for electrical connection and monitoring.
Data Source
AI summary
Battery arrays are provided for traction battery packs. An exemplary battery array may include an integrated battery interconnect assembly that is configured to electrically connect a plurality of battery cells. The various subcomponents of the integrated battery interconnect assembly may be either preassembled or physically formed together to establish a unitary, integrated component adapted for electrically connecting the battery cells, thereby reducing parts count and complexity.