Battery Pack Busbar Frame Layout for Short-Circuit Prevention
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Solution Overview
Problem
In electric vehicle battery packs, short circuits can occur between the busbar and battery modules due to interference, which affects the reliability and safety of the battery pack.
Innovation Solution
A battery pack design where a busbar is positioned between two adjacent battery modules, supported by a base plate and a support member, with a busbar frame that stabilizes the busbar and prevents short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the busbar is disposed between two adjacent battery modules, then the risk of short circuit is reduced, but the device complexity increases due to additional support structures
Solution Approach 1:
The busbar frame is nested within the support member, with the busbar nested within the busbar frame. This nested structure allows multiple components to occupy the same spatial envelope, reducing overall complexity while maintaining the busbar's isolated position between battery modules for short circuit prevention.
Solution Approach 2:
The busbar frame acts as an intermediary component between the busbar and the support member, providing a dedicated mounting structure that isolates the busbar from direct contact with battery modules. This intermediary structure simplifies the overall design by creating a clear separation hierarchy.
2Reliability
If the busbar is positioned between battery modules, then safety is improved by preventing short circuits, but the manufacturing precision requirements increase for proper alignment
Solution Approach 1:
The support member and busbar frame are pre-configured with positioning features (protrusions and recesses) that guide the busbar into its correct position between battery modules during assembly. This preliminary structural preparation reduces the precision requirements during final assembly by providing mechanical guidance.
Solution Approach 2:
The busbar frame serves as an intermediary that pre-establishes the correct spatial relationship between the busbar and battery modules. By fixing the busbar within the frame at the appropriate position, the system reduces alignment precision requirements during assembly.
3Reliability
If support members and busbar frames are added to prevent short circuits, then reliability is improved, but the weight of the battery pack increases
Solution Approach 1:
The support member serves multiple functions: it provides structural support for the battery modules, positions the busbar frame, and contributes to overall pack rigidity. This multi-functionality reduces the need for separate components, thereby minimizing weight addition while maintaining short circuit prevention capabilities.
Solution Approach 2:
The busbar frame is integrated with the support member structure, combining the busbar mounting function with the structural support function. This merging of functions eliminates redundant components and reduces overall weight while maintaining the isolation of the busbar from battery modules.
Data Source
AI summary
A battery pack includes: a first battery module, a second battery module spaced apart from the first battery module in a first direction, a base plate that supports the first battery module and the second battery module, a support member supported by the base plate, and extending in a second direction crossing the first direction in a space between the first battery module and the second battery module, and a busbar extending from an upper side of the support member in the second direction through the space between the first battery module and the second battery module.