Battery Pack Bus Bar Layout With Glue Injection Ports
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Solution Overview
Problem
Existing cylindrical power battery packs face challenges with the routing and arrangement of long copper bus bars, which occupy significant space and are prone to short-circuiting, and the uneven foaming of foam glue used for assembly, leading to installation difficulties and potential welding issues.
Innovation Solution
A bus bar design with working portions that connect cells in parallel, featuring glue injection ports and weakened holes to facilitate uniform foaming and reduce the risk of short-circuiting, along with a bus bar assembly that includes series and electrode bars to improve the structural integrity and safety of the battery pack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If long copper bars are arranged and extended along the circumference of the inner side of the battery pack, then the cells can be connected in series and parallel, but a large space is occupied and there is a risk that the copper bars are difficult to install and are easily short-circuited upon squeezing the battery pack
Solution Approach 1:
The bus bar is divided into multiple working portions arranged in the width direction, with each working portion connecting a specific pair of adjacent cells. This segmentation allows the bus bar to be routed through narrow gaps between cells rather than extending along the circumference, reducing space occupation while maintaining connection reliability
Solution Approach 2:
The bus bar structure transitions from a single long circumferential bar to multiple segmented portions distributed across the width direction of the battery pack. This dimensional redistribution enables the bus bar to utilize the width direction space efficiently, reducing overall space occupation while maintaining all necessary electrical connections
2Stability of the object's composition
If foam glue is foamed in the horizontal direction into the gaps between the cells, then the components and case are solidified into an integral structure, but the gaps between the cells are narrow making it difficult to inject the foam glue, causing uneven foaming
Solution Approach 1:
The foam glue injection process is segmented by introducing multiple injection ports distributed across different locations, including through the bus bar working portions. This allows foam glue to be injected into multiple narrow gaps simultaneously, ensuring uniform foaming throughout the battery pack while maintaining assembly stability
Solution Approach 2:
The bus bar working portions serve as intermediary structures that incorporate injection ports, facilitating the introduction of foam glue into narrow gaps between cells. This intermediary approach enables controlled and uniform foam glue distribution in difficult-to-reach areas
3Stability of the object's composition
If foam glue is foamed in the longitudinal direction, then the assembly is solidified, but an upward jacking force is provided to the welded bus bars, creating a risk that the bus bars and cells are not welded off
Solution Approach 1:
The bus bar working portions are designed with reinforced structures and proper welding configurations beforehand to withstand the upward jacking force generated during longitudinal foam glue foaming. This preemptive design ensures welding reliability is maintained despite the mechanical stress during assembly solidification
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 solution enables efficient and uniform injection of foam glue, reduces the risk of bus bar welding failure, and enhances the structural stability and safety of the battery pack by minimizing space occupation and preventing short-circuits, while maintaining high energy density.
Implementation Method 1
the foam glue is foamed in the horizontal direction into the gaps between the cells, the gaps between the battery modules, and the gaps between the battery module and the inner wall of the case
Implementation Method 2
during longitudinal foaming of the foam glue, an upward jacking force in the longitudinal direction is provided to the welded bus bars
Data Source
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AI summary
The present application provides a bus bar, a bus bar assembly, and a battery pack. The bus bar includes a plurality of working portions arranged and connected in a width direction of a battery module, the working portions is arranged in one-to-one correspondence with rows of cells arranged in a width direction. The working portion includes a positive electrode portion and a negative electrode portion connected to each other. The positive electrode portion is connected to a positive terminal of one of two adjacent cells in a length direction; and the negative electrode portion is connected to a negative terminal of another of the two adjacent cells in the length direction. The positive electrode portion and the negative electrode portion are provided with at least one of glue injection ports communicating with a gap between the two adjacent cells connected by the working portion in series.