Integrated Bus Bar Frame for Pouch Cell Battery Pack Assembly
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Solution Overview
Problem
Existing battery packs face challenges in achieving high energy density and efficient manufacturing due to complex assembly processes and numerous components.
Innovation Solution
A battery pack design featuring a bus bar frame that covers multiple battery assemblies, reducing the number of assembly processes and components, with a fire-resistant sheet and inter-bus bars for improved electrical connections and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional battery pack assembly with multiple separate bus bars is used, then electrical connectivity is achieved, but assembly complexity and component count increase
Solution Approach 1:
The patent combines multiple separate bus bars into a single integrated bus bar assembly that spans across multiple battery assemblies. This unified structure reduces the total number of components and simplifies assembly while maintaining all necessary electrical connections through strategically positioned connection points and conductive elements.
Solution Approach 2:
The bus bar assembly serves multiple functions simultaneously: it provides electrical connectivity between multiple battery assemblies, structural support for the battery pack, and thermal management pathways. This multi-functionality reduces the need for separate dedicated components for each function.
2Reliability
If more components are used for thermal management and electrical connections, then safety and functionality improve, but manufacturing cost and assembly time increase
Solution Approach 1:
The fire-resistant sheet is integrated directly into the bus bar assembly structure, combining thermal management and safety functions with the electrical connection system. This eliminates the need for separate safety components and reduces assembly steps.
Solution Approach 2:
The bus bar assembly incorporates fire-resistant materials composite with conductive elements, creating a multi-functional component that provides both electrical connectivity and thermal/safety protection simultaneously, reducing the need for multiple separate components.
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 design enhances energy density and productivity by simplifying assembly and reducing component count, while providing effective thermal management and electrical connectivity.
Implementation Method 1
The positive electrode lead and the negative electrode lead of each of the plurality of pouch type battery cells may be welded together with the corresponding one of the plurality of inter-bus bars.
Implementation Method 2
The bus bar assembly may further include a fire-resistant sheet between the first and second battery assemblies and the bus bar frame.
Data Source
AI summary
A battery pack may include a housing, first and second battery assemblies on the housing and each including a plurality of pouch type battery cells, and a bus bar assembly on the first and second battery assemblies. In addition, the bus bar assembly may include a bus bar frame configured to cover the first and second battery assemblies, and a plurality of inter-bus bars on the bus bar frame.