Battery Pack Busbar Assembly with Breakable Bridge
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Solution Overview
Problem
The complex and time-consuming manufacturing processes of battery packs, particularly in accommodating multiple cell stacks, hinder efficient production and quick response to overcurrent events.
Innovation Solution
A battery pack design featuring a busbar assembly with a bridge busbar that includes a breakable portion made of aluminum, embedded in a copper support plate, allowing for rapid overcurrent cutoff and simplified manufacturing by eliminating the need for additional connection members between cell stacks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple battery modules are accommodated in a battery pack, then the battery pack capacity is increased, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent combines multiple cell stacks (first cell stack and second cell stack) into a single integrated battery assembly. The busbar assembly serves as a common electrical connection structure that simultaneously connects both cell stacks, eliminating the need for separate connection processes for each stack and reducing overall manufacturing complexity.
Solution Approach 2:
The busbar assembly performs multiple functions: it provides electrical connection for both the first and second cell stacks, serves as a structural support element, and acts as a heat dissipation pathway. This multi-functionality reduces the number of separate components needed and simplifies the manufacturing process.
2Quantity of substance
If multiple battery modules are accommodated in a battery pack, then the battery pack capacity is increased, but the manufacturing time is extended
Solution Approach 1:
The patent combines multiple cell stacks (first cell stack and second cell stack) into a single integrated battery assembly. The busbar assembly serves as a common electrical connection structure that simultaneously connects both cell stacks, eliminating the need for separate connection processes for each stack and reducing overall manufacturing complexity.
Solution Approach 2:
The busbar assembly is designed and prepared in advance as a pre-assembled unit that can be quickly installed to connect multiple cell stacks. This preliminary preparation of the connection structure enables faster assembly during the battery pack manufacturing process.
3Reliability
If a bridge busbar is used to connect cell stacks, then overcurrent cutoff speed is improved, but the busbar structure becomes more complex
Solution Approach 1:
The bridge busbar includes a breakable portion with different material properties (lower melting point) located specifically at the section that needs to break during overcurrent events. This localized differentiation allows the busbar to maintain structural integrity in most areas while having a specific weak point for rapid failure when needed.
Solution Approach 2:
The bridge busbar is formed as an integral structure with portions made of different materials - the main body uses a high-melting-point material for structural strength, while the breakable portion uses a lower-melting-point material for rapid failure during overcurrent events. This composite construction enables both structural integrity and rapid overcurrent response.
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
Facilitates quicker manufacturing and ensures reliable overcurrent protection by enabling rapid disconnection of electrical connections during overcurrent events, enhancing the stability and efficiency of battery pack assembly.
Implementation Method 1
the breakable portion may be fused at a temperature lower than a melting point of the bus bar
Implementation Method 2
a busbar assembly electrically connecting the plurality of battery cells to each other
Data Source
AI summary
A battery pack includes a pack housing, and at least one battery assembly accommodated in the pack housing. The battery assembly includes a first cell stack and a second cell stack in each of which a plurality of battery cells are stacked, and a busbar assembly electrically connecting the plurality of battery cells to each other. The busbar assembly includes a first coupling portion coupled to the first cell stack, a second coupling portion coupled to the second cell stack, and a connection portion connecting the first coupling portion and the second coupling portion to each other.