Traction Battery Busbar Compensation Section for Cell Movement
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Solution Overview
Problem
The relative movement of cells within a traction battery due to mechanical forces or thermal expansion can lead to a loss of electrical connection between the busbar and cells, causing a disruption in the connection assembly of an electric vehicle.
Innovation Solution
Incorporating compensation sections on both the busbar and flexible electrical connection element that extend perpendicular to the main extension direction, allowing for elastic deformation and maintaining contact during relative movement, with the busbar made from flat sheet metal and the flexible connection element being a flexible flat cable, ensuring a force-free contact and preventing electrical disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the busbar and flexible electrical connection element extend straight along the extension direction, then the electrical connection is simple and direct, but the connection is lost when cells move relative to each other due to mechanical forces or thermal expansion
Solution Approach 1:
The busbar incorporates a compensation section with a curved shape that allows dynamic adjustment. When cells move relative to each other due to mechanical forces or thermal expansion, the curved compensation section deforms elastically to accommodate the displacement while maintaining continuous electrical contact, transforming the rigid straight structure into a dynamically adaptable one.
Solution Approach 2:
The compensation section changes the geometric parameters of the busbar by introducing a curved shape instead of a straight line. This curvature provides the necessary degrees of freedom for the busbar to adapt its shape in response to cell movements, enabling the structure to maintain contact under varying positional conditions.
2Stability of the object's composition
If the busbar is made rigid to maintain stable connection, then structural stability is improved, but the ability to accommodate cell movement and thermal expansion is reduced
Solution Approach 1:
The compensation section transforms the rigid busbar into a semi-flexible structure. The curved geometry allows the busbar to deform within certain limits while maintaining overall structural integrity and stable electrical connection, achieving both stability and adaptability simultaneously.
Solution Approach 2:
The compensation section acts as a flexible element within the busbar structure. Its curved shape enables elastic deformation to accommodate cell movements and thermal expansion, providing the necessary flexibility while the busbar maintains its structural function and electrical conductivity.
3Adaptability or versatility
If compensation sections are added to accommodate cell movement, then adaptability to relative movement is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The compensation section uses a curved geometric shape that can be formed from flat sheet metal through bending processes. This curvature provides the necessary adaptability for cell movement compensation while being manufacturable using standard metal forming techniques, balancing complexity and ease of manufacture.
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 effectively allows for relative movement of cells without losing electrical contact, ensuring reliable operation and integrity of the connection assembly by using nested compensation sections that enable hinged movement and maintain contact between the busbar and cells.
Implementation Method 1
The busbar has a compensation section in which the busbar extends perpendicular with respect to the extension direction... allowing for elastic deformation and maintaining contact during relative movement
Data Source
AI summary
A connection assembly for a traction battery comprises a busbar extending in an extension direction and a flexible electrical connection element extending along the busbar in the extension direction. The busbar has a compensation section in which the busbar extends perpendicular with respect to the extension direction.