Integrated Bus Bar Assembly for Parallel Battery Array Coupling
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Solution Overview
Problem
Existing electrified vehicle traction battery packs face challenges in reliably connecting adjacent battery arrays to achieve the necessary voltage and power levels for propulsion, requiring effective electrical coupling solutions to ensure efficient energy distribution.
Innovation Solution
The use of bus bar assemblies with combined and component electrical interfaces, configured to connect multiple battery arrays in parallel configurations, including a cover to expose interfaces for secure connections, and designed to handle high voltage outputs, enabling efficient electrical coupling and current distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bus bar assemblies are used to connect multiple battery arrays in parallel, then electrical coupling reliability and power distribution efficiency are improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent combines multiple electrical interfaces (first component electrical interface, second component electrical interface, and combined electrical interface) into a single integrated bus bar assembly. This merging approach ensures reliable parallel electrical coupling between multiple battery arrays while maintaining a unified structural design that manages complexity through functional integration rather than separate discrete components.
2Power
If larger cross-sectional area bus bars are used for combined electrical interfaces, then current carrying capacity and power distribution are improved, but weight and material usage increase
Solution Approach 1:
The bus bar assembly implements local quality by providing a combined electrical interface with a larger cross-sectional area than individual component interfaces. This localized increase in cross-sectional area at the combined interface optimizes current carrying capacity where multiple parallel currents converge, while maintaining smaller cross-sections in individual connection points, thus managing overall weight and material usage efficiently.
3Power
If bus bar assemblies are designed for parallel configuration connections, then voltage and power levels for propulsion are achieved, but manufacturing precision requirements increase
Solution Approach 1:
The bus bar assembly is designed with universal multi-functionality, where a single assembly type can connect multiple battery arrays in parallel configurations to achieve the required voltage and power levels. The standardized interface design with multiple connection points (first component interface, second component interface, and combined interface) provides a universal solution that reduces manufacturing precision requirements by using consistent connection geometries across all battery array connections.
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 solution allows for reliable and efficient electrical coupling of battery arrays, optimizing power distribution, reducing heat generation, and potentially eliminating the need for active bus bar cooling, while providing modularity and flexibility in battery pack configurations.
Implementation Method 1
a bus bar assembly configured to electrically couple the first and second battery arrays in a parallel configuration. The bus bar assembly includes a bus bar having a first component electrical interface connected to the first battery array, and a second component electrical interface connected to the second battery array
Data Source
AI summary
Exemplary bus bar assemblies may be used to electrically couple adjacent components of electrified vehicle traction battery packs, for example. An exemplary bus bar assembly may include a bus bar and a cover disposed about portions of the bus bar. The bus bar may include a single combined electrical interface section and multiple component electrical interface sections for connecting multiple traction battery pack electrical components in parallel configurations.