Battery Pack Parallel Conductor Routing for Lower Busbar Mass
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High-voltage electrochemical battery packs require large transfer conductors to handle the full battery current, leading to increased mass, packaging space, and material usage.
Innovation Solution
The battery pack is configured with parallel-connected battery sections, allowing the transfer conductors to handle only half of the total battery current, which reduces their size and mass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If series-connected battery sections are used, then the transfer conductors can handle the full battery current, but the mass and packaging space increase significantly
Solution Approach 1:
The battery pack is divided into multiple parallel-connected battery sections, each handling a portion of the total current. This segmentation allows the use of smaller, lighter transfer conductors in each section while collectively maintaining the full current handling capability of the battery pack.
2Reliability
If series-connected battery sections are used, then the full battery current flows through each transfer conductor, but the packaging space and material usage increase
Solution Approach 1:
The battery system is segmented into parallel sections with dedicated transfer conductors for each section. This reduces the cross-sectional area and volume of individual conductors needed, thereby decreasing overall packaging space requirements while maintaining total current capacity.
3Reliability
If larger transfer conductors are used to handle full battery current, then the current handling capability is sufficient, but the mass increases
Solution Approach 1:
By segmenting the battery pack into parallel-connected sections, each section requires transfer conductors sized for only a portion of the total current. This reduces the mass of individual conductors and the overall conductor mass in the system while preserving the ability to handle the full battery current collectively.
4Weight of stationary object
If parallel-connected battery sections are used, then the transfer conductors can be smaller and lighter, but the battery pack configuration becomes more complex
Solution Approach 1:
The battery pack is organized into modular parallel-connected sections, each with its own transfer conductors. This segmentation approach, while reducing conductor mass, introduces additional connection points and routing complexity that must be managed through careful system design and layout.
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 configuration results in a significant reduction in mass, packaging space, and conductive material required, while maintaining the ability to handle the total battery current.
Implementation Method 1
a total battery current flowing through the battery pack is evenly divided across the two parallel-connected battery sections, with busbars, cables, or other suitable transfer conductors of the battery pack being rated for half of the total battery current
Data Source
AI summary
A battery pack for a direct current (DC) voltage bus includes a battery disconnect unit (BDU) operable for controlling a connection state of the battery pack with respect to the DC voltage bus, first and second battery sections, and six transfer conductors, e.g., busbars or cables/wires. The first battery section has first and second battery modules with corresponding battery cells. The first and second battery modules are connected in series. The first and second battery sections are connected in parallel. The second battery section has third and fourth battery modules each with additional battery cells, with the third and fourth battery modules connected in series. The six transfer conductors collectively interconnect the battery modules, sections, and BDU. A total battery current is divided equally between the battery sections, with the transfer conductors being rated for half of the total battery current.