Battery Pack Busbar Assembly With Filler Injection for Higher Energy Density
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Solution Overview
Problem
There is a need for battery packs with higher energy density and a simpler structure that can be manufactured more efficiently and at reduced cost.
Innovation Solution
A battery pack design incorporating a plurality of battery cells, a filler member, and a busbar assembly with filler member injection holes, allowing for simultaneous electrical connection and injection of the filler member, which includes a mixture of resin and glass bubbles, and a busbar assembly with busbar covers and sub-busbars for improved connectivity and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If battery cells are connected in series/parallel to form a battery pack, then output voltage and charge/discharge capacity are improved, but structure complexity and manufacturing time increase
Solution Approach 1:
The busbar assembly integrates multiple functions into a single component: electrical connection between battery cells, injection hole formation for filler member delivery, and structural support. This merging of functions reduces the number of separate components needed and simplifies the overall battery pack structure while maintaining the required power output through series/parallel cell connections
2Ease of manufacture
If traditional battery pack manufacturing processes are used, then electrical connection is achieved, but manufacturing time and cost increase due to separate injection processes
Solution Approach 1:
The manufacturing process merges the electrical connection step and filler member injection step into a single integrated operation. The busbar assembly is positioned and electrically connected while simultaneously serving as the injection conduit for the filler member, eliminating the need for separate injection processes and reducing manufacturing time
Solution Approach 2:
The busbar assembly is pre-configured with injection holes formed before or during the electrical connection process. This preliminary preparation of the injection pathways allows the filler member to be injected immediately after busbar assembly installation, eliminating the need for separate injection equipment and operations
Data Source
AI summary
A battery pack according to an embodiment of the present disclosure includes a plurality of battery cells, a filler member filled in a space between the plurality of battery cells, and a busbar assembly electrically connected to the plurality of battery cells, and having a filler member injection hole for injecting the filler member.