Integrated Bus Bar and Sense Lead for EV Battery Assembly
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Solution Overview
Problem
Conventional bus bar assemblies for electrified vehicles face challenges in reliably connecting battery cells with varying terminal heights, requiring complex components like separate sense lead wires and crimpings, which complicate the assembly process and may lead to inefficiencies in power distribution.
Innovation Solution
A bus bar assembly incorporating a flexible cable with integrated voltage sense leads and a bus bar connected to the sense lead, accommodating terminal height variations and simplifying the assembly by using welding or jumper wires for connections, allowing for efficient electrical connection of battery cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate bus bars and sense lead wires are used to connect battery cells, then reliable electrical connection is achieved, but device complexity increases
Solution Approach 1:
The patent combines the bus bar and sense lead wire into a single integrated assembly. The sense lead wire is attached to the bus bar, creating a unified component that performs both power transmission and voltage sensing functions, thereby reducing the number of separate parts and simplifying the assembly process while maintaining reliable electrical connections
2Adaptability or versatility
If multiple separate components are used for battery cell connection, then adaptability to terminal height variations is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent employs a flexible cable assembly that can bend and adjust to accommodate variations in battery cell terminal heights. This dynamic flexibility allows the same integrated bus bar and sense lead wire assembly to adapt to different terminal positions without requiring multiple specialized components, simplifying manufacturing while maintaining adaptability
3Ease of manufacture
If integrated voltage sense leads are used with flexible cable, then assembly process is simplified, but connection reliability may be compromised
Solution Approach 1:
The patent uses a flexible cable with integrated voltage sense leads that maintains reliable electrical connections through its curved and flexible design. The cable's flexibility allows it to conform to the battery cell arrangement while the integrated sense leads remain properly positioned and connected, ensuring both assembly simplicity and connection reliability
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 reliable and efficient electrical connection of battery cells, accommodating height variations and simplifying the assembly process, thereby improving power distribution and reducing complexity in electrified vehicle battery assemblies.
Implementation Method 1
the bus bar is welded to the voltage sense lead
Data Source
AI summary
A bus bar assembly according to an exemplary aspect of the present disclosure includes, among other things, a plurality of battery cells and a bus bar assembly that electrically connects the plurality of battery cells. The bus bar assembly includes a flexible cable, a voltage sense lead connected to the flexible cable, and a bus bar connected to the voltage sense lead.