Battery Pack Busbar Assembly for Compact Stable Cell Connections
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Solution Overview
Problem
Existing battery modules and packs face challenges with inefficient space utilization due to the use of injection-molded busbar frames, which hinder effective assembly and manufacturing processes.
Innovation Solution
A battery pack design featuring a busbar assembly with a simplified shape, including a busbar, circuit board, and insulating film, which is laminated to prevent movement and reduce volume, along with a conductive adhesive for easy electrical connections and a support part for stability, enhancing space utilization and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an injection-molded busbar frame is used, then the structural strength is improved, but the space utilization deteriorates
Solution Approach 1:
The busbar assembly is divided into separate components: the busbar, circuit board, and insulating film are manufactured independently and then assembled together. This segmentation allows each component to be optimized separately, reducing overall volume while maintaining structural strength through proper assembly design.
Solution Approach 2:
The circuit board is positioned within the busbar structure, and the insulating film is laminated over both components. This nested arrangement allows multiple functional elements to occupy overlapping or adjacent spaces, maximizing space utilization while preserving the structural integrity of the busbar frame.
2Reliability
If a complex busbar frame structure is used, then the electrical connection reliability is improved, but the manufacturing complexity increases
Solution Approach 1:
The electrical connection system is segmented into the busbar for current collection, the circuit board for control functions, and the insulating film for electrical isolation. This segmentation allows each component to be manufactured using standard processes, reducing overall manufacturing complexity while ensuring reliable electrical connections through dedicated functional zones.
Solution Approach 2:
The insulating film serves as an intermediary component between the busbar and circuit board, providing electrical isolation while allowing mechanical assembly. This intermediary element simplifies the manufacturing process by enabling straightforward assembly procedures and ensuring reliable electrical connections without requiring complex integration techniques.
3Volume of moving object
If the busbar assembly volume is reduced, then the space utilization is improved, but the assembly stability deteriorates
Solution Approach 1:
The compact busbar assembly achieves stability through nested positioning where the circuit board is supported by the busbar structure and both are secured by the insulating film. This nested configuration maximizes space utilization while maintaining assembly stability through mutual support and constraint of all components within a compact volume.
Solution Approach 2:
The insulating film acts as a flexible yet rigidifying element that laminates over the busbar and circuit board, providing mechanical support and stabilization. This thin film structure enables volume reduction while preventing component movement and maintaining assembly stability through distributed mechanical constraint.
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 simplified busbar assembly reduces volume, improves space utilization, simplifies manufacturing and assembly processes, and enhances electrical connections, leading to more efficient battery pack production.
Implementation Method 1
a conductive adhesive attached to one surface of the connection part to electrically connect the connection part to the busbar
Implementation Method 2
a film laminated on the busbar and the circuit board to prevent the busbar and the circuit board from moving
Data Source
AI summary
Disclosed herein is a battery pack with a busbar assembly. The busbar assembly is simplified in shape and reduced in volume to improve space utilization and manufacturing efficiency of the battery pack.The battery pack can include a plurality of cell groups with one or more cells and a terminal, and a busbar assembly disposed on one end of a top surface of each of the cell groups. The busbar assembly can include a busbar disposed adjacent the terminal to electrically connect the cell groups to each other, a circuit board electrically connected to the busbar to sense the cell groups, and a film laminated on the busbar and the circuit board to prevent the busbar and the circuit board from moving.