Battery Lid Busbar Layout for Simpler Cell Pack Assembly
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Solution Overview
Problem
Existing battery designs face challenges in efficiently connecting a cell pack to terminals within a battery housing, often requiring cumbersome thick cables that need to be managed and coiled during assembly, complicating the process.
Innovation Solution
The use of busbars that electrically couple the cell pack to terminals through a sloped and/or stepped configuration, allowing connections to be made after the lid is placed over the housing, reducing the need for thick cables and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thick cables are used to connect cell pack to terminals, then electrical connection is achieved, but assembly complexity and cable management difficulty increase
Solution Approach 1:
The busbar is divided into multiple segments (first busbar segment, second busbar segment) that can be independently positioned and connected. The first segment connects to the cell pack while the second segment connects to the lid, allowing separate assembly steps and reducing overall assembly complexity
Solution Approach 2:
The busbar acts as an intermediary component between the cell pack and terminals, eliminating the need for thick flexible cables. The busbar provides a rigid electrical connection path that integrates with the battery structure, simplifying cable management while maintaining reliable electrical connection
2Reliability
If thick cables are used to connect cell pack to terminals, then electrical connection is achieved, but the assembly process becomes more complicated
Solution Approach 1:
The busbar is pre-configured with specific geometries (sloped and/or stepped shapes) and pre-positioned within the housing before final assembly. The first end of the busbar is positioned closer to the open end of the housing, allowing preliminary connections to be made before the lid is fully installed
Solution Approach 2:
The busbar employs sloped and/or stepped three-dimensional geometries instead of simple linear cables. This dimensional complexity in the busbar structure replaces the need for complex cable routing, simplifying the overall assembly process while maintaining electrical connection reliability
3Device complexity
If busbar with sloped and/or stepped configuration is used, then cable management is simplified, but manufacturing complexity increases
Solution Approach 1:
The busbar geometry parameters (slopes, steps, angles) are optimized to achieve the desired cable management simplification while remaining manufacturable. The specific sloped and stepped configurations are designed to balance manufacturing complexity with assembly simplicity and electrical connection efficiency
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables efficient and streamlined high-voltage electrical connections between the cell pack and terminals, simplifying the assembly process and reducing the complexity of cable management during battery construction.
Implementation Method 1
A first busbar is configured to electrically couple the cell pack to the first terminal
Data Source
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AI summary
A battery (10) has a housing (20), a cell pack (30) supported within the housing (20), and a lid (40) configured to close an open end (21) of the housing (20). A first terminal (71) is supported by the lid (40). A first busbar (61) is configured to electrically couple the cell pack (30) to the first terminal (71). A first electrical component (83, 84, 102) is supported by the lid (40) and electrically coupled between the first busbar (61) and the first terminal (71).