Battery Spacer Retainer Integrates Busbar and Sensor
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Solution Overview
Problem
Existing battery assembly designs for electric vehicles require multiple components for busbar attachment, increasing production costs and complexity, while also lacking efficient integration of temperature sensors for accurate cell temperature monitoring.
Innovation Solution
The use of spacers with integrated retainers and busbar modules that include protective housings and pivotable flaps to secure busbars and temperature sensors directly to the battery array, reducing the need for additional attachment components and enhancing sensor accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate components are used for busbar attachment, then the busbar can be securely attached to the battery array, but the production cost and assembly complexity increase
Solution Approach 1:
The retainer is integrated directly into the spacer structure, combining the spacing function with the busbar retention function into a single component. This eliminates the need for separate attachment components while maintaining secure busbar attachment to the battery array terminals
Solution Approach 2:
The spacer serves multiple functions simultaneously: it provides electrical isolation between adjacent battery cells, maintains proper cell spacing for thermal management, and incorporates retainers that secure busbars to the terminals. This multi-functionality reduces the total component count and simplifies assembly
2Measurement precision
If temperature sensors are integrated within the busbar modules, then sensor accuracy for cell temperature monitoring is improved, but the manufacturing complexity increases
Solution Approach 1:
The temperature sensor is integrated within the busbar module housing, combining the electrical connection function with the temperature monitoring function. This placement improves measurement accuracy by positioning the sensor directly at the cell terminal where temperature is most critical, while the modular design facilitates straightforward manufacturing and assembly
3Device complexity
If spacers with integrated retainers are used, then the number of components is reduced and production costs decrease, but the manufacturing precision requirements increase
Solution Approach 1:
The retainers are pre-formed as integral parts of the spacers during the molding or fabrication process, rather than being attached as separate components. This preliminary integration ensures precise positioning and eliminates the need for additional assembly steps, reducing both manufacturing complexity and the risk of positioning errors
Data Source
AI summary
A battery assembly includes a plurality of cells stacked to form an array and a plurality of spacers each disposed between an adjacent pair of the cells. Each cell includes at least one terminal. Each of the spacers includes a retainer extending from an edge portion of the spacer. The retainers are configured to orient and engage a busbar for connecting the terminals of an adjacent pair of cells. The battery assembly may also include a busbar module. The busbar module may engage with the retainers to hold the busbar module to the array.