Busbar Grid Fixation for Battery Tray Rigidity
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Solution Overview
Problem
The manufacturing of electric vehicle battery systems faces challenges in reducing costs while ensuring reliability and safety, particularly in making efficient electrical connections and providing mechanical support for the large number of individual battery cells, which are crucial for efficient operation and safety.
Innovation Solution
The use of busbars that provide both electrical conductivity and mechanical support to battery packs, with thin plastic trays and conductive busbars of specific thicknesses, along with cooling ducts for thermal management, to facilitate efficient assembly and replacement of battery cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional thick plastic trays are used to provide mechanical support for battery cells, then structural strength is improved, but weight and space increase
Solution Approach 1:
The busbar is merged with the tray structure to form an integrated component that provides both electrical connection and mechanical support functions, eliminating the need for separate thick plastic trays and reducing overall weight
Solution Approach 2:
The busbar serves multiple functions simultaneously: electrical conduction, mechanical support for battery cells, and structural reinforcement of the tray, replacing what would traditionally require multiple separate components
2Device complexity
If busbars are used to provide both electrical conductivity and mechanical support, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The busbar thickness is optimized to a specific range (1-2mm) that balances mechanical strength requirements with manufacturing feasibility, allowing thin-section extrusion processes to achieve the needed precision without excessive complexity
3Weight of stationary object
If thin plastic trays are used to reduce weight, then weight and space are reduced, but structural rigidity deteriorates
Solution Approach 1:
The thin tray is merged with the busbar structure where the busbar acts as a reinforcing element within or alongside the thin plastic tray, providing the necessary rigidity without requiring the tray material itself to be thick
Solution Approach 2:
The tray-busbar combination creates a composite structure where the thin plastic tray provides form and the metal busbar provides structural reinforcement, achieving both weight reduction and rigidity maintenance
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
This solution enhances the rigidity and reliability of battery packs, reduces manufacturing complexity, and allows for thinner trays, thereby minimizing space and weight, while ensuring safe and efficient electrical connections and thermal management.
Implementation Method 1
The battery packs include one or more busbars that can conduct electrical energy to and from at least the subset of battery cells
Implementation Method 2
the rigidity of the combination of the upper tray and the first busbar is provided predominantly by the first busbar
Data Source
AI summary
A rechargeable battery system, a battery pack, methods of manufacturing the same, and an electric vehicle are disclosed herein. The battery pack includes an upper tray, a first busbar attached to the upper tray, a lower tray, a second busbar attached to the lower tray, and a plurality of battery cells arranged in the upper and lower trays. The rigidity of the combination of the upper tray and the first busbar is provided predominantly by the first busbar.