Battery Module Busbar Assembly for Simpler EV Pack Connections
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Solution Overview
Problem
Electric vehicle batteries require standardized modules with excellent electrical and mechanical performance to withstand harsh driving conditions, and existing solutions complicate manufacturing with multiple bending and welding processes, leading to inefficiencies and increased development costs.
Innovation Solution
A battery module design featuring laminated battery cells with busbar assemblies for simplified electrical connections, clamps for stiffness, and a modular structure allowing standardized application across various vehicle types, with busbar assemblies enabling one bending and welding process for improved manufacturing quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple bending and welding processes are used for electrical connections, then connection reliability is improved, but manufacturing complexity and development costs increase
Solution Approach 1:
The busbar assembly integrates multiple electrical connection functions into a single component structure. The busbar is designed with multiple connection points and bending sections that can simultaneously connect to multiple battery cells, reducing the need for separate bending and welding operations for each connection point.
Solution Approach 2:
The busbar assembly serves multiple functions: it provides electrical connection, structural support, and thermal management pathways. The integrated design allows a single component to perform what previously required multiple separate components and processes.
2Adaptability or versatility
If standardized battery modules are designed for various vehicle types, then adaptability is improved, but design flexibility for specific vehicle requirements may be reduced
Solution Approach 1:
The battery system is divided into standardized module units that can be independently designed, manufactured, and assembled. Each module contains a complete set of busbar assemblies and battery cells configured for standard connection patterns, allowing modular scaling for different vehicle applications.
Solution Approach 2:
The standardized busbar assembly design can be applied across different battery cell types and configurations. The modular architecture allows the same basic module design to serve multiple vehicle types by simply changing the number of modules assembled rather than redesigning the entire system.
3Volume of moving object
If battery cells are tightly laminated for compactness, then space utilization is improved, but heat dissipation capability may be reduced
Solution Approach 1:
The busbar assembly creates localized thermal management pathways between battery cells. The metal busbar contacts provide thermal conduction channels that allow heat to dissipate from high-density cell regions without requiring increased overall spacing between cells.
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
The solution provides enhanced mechanical robustness, simplified manufacturing, and reduced development costs by allowing standardized battery modules to be applied across different vehicle specifications, while effectively managing heat dissipation and voltage monitoring.
Implementation Method 1
a busbar configured to mutually join electrodes of a plurality of battery cells located at the both ends in the second direction
Implementation Method 2
a pair of clamps respectively joined to both ends of the battery module in the first direction, each comprising a clamp body and a fastening part extending from the clamp body in an inserted state in a clamp hole
Data Source
AI summary
A battery pack includes a plurality of battery modules, and each battery module includes: a plurality of battery cells mutually laminated in a first direction and forming a laminated structure; a pair of end plates, each end plate of the pair of end plates being in surface contact with a first and a second ends of the laminated structure, respectively, in the first direction; and a pair of busbar assemblies. In particular, each bus bar assembly of the pair of bus bar assemblies is disposed at the first end and the second end of the laminated structure, respectively, in a second direction perpendicular to the first direction.