Vehicle Traction Battery Busbar Interlocking and Weld Spot Design
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Solution Overview
Problem
Existing busbar designs for vehicle traction batteries face challenges in securely and efficiently interlocking with battery cells, particularly in providing adequate space for weld spots and ensuring flush contact, which can affect electrical connectivity and reliability.
Innovation Solution
The design incorporates a busbar with arms and trough members that interlock with the battery cells' ridges, featuring terminal apertures spaced for weld spots and raised portions to accommodate varying cell heights, ensuring secure electrical connection and flexibility through cutouts for accommodating different cell configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the busbar uses a simple flat design, then the manufacturing is easier, but the interlocking with battery cells is insufficient and weld spot space is inadequate
Solution Approach 1:
The busbar is segmented into multiple functional zones including ridges for interlocking, flat regions for weld spots, and tapered transitions. This segmentation allows each region to perform its specific function optimally while maintaining overall manufacturing feasibility through stamping or extrusion processes
Solution Approach 2:
Different regions of the busbar have different local geometries optimized for their specific functions: ridges with specific heights and spacing for interlocking with cell valleys, flat regions with adequate surface area for weld spots, and tapered regions for stress distribution. This local quality variation resolves the contradiction between manufacturing simplicity and connection reliability
2Volume of moving object
If the terminal aperture is positioned close to the edge for compact design, then the device size is reduced, but adequate space for weld spots is not provided
Solution Approach 1:
The busbar design utilizes the width dimension extensively by positioning terminal apertures centrally with adequate spacing to outer edges, creating flat regions on either side of each aperture. This dimensional arrangement provides sufficient weld spot space while maintaining compact overall busbar dimensions through optimized aperture spacing and width utilization
3Reliability
If the busbar height is increased to cover more cell surface for better contact, then the electrical connectivity is improved, but the adaptability to different cell heights is reduced
Solution Approach 1:
The busbar incorporates tapered transitions between ridges and flat regions, allowing the structure to adapt to varying cell heights dynamically. The tapered geometry enables the busbar to maintain flush contact with cells of different heights while preserving adequate weld spot space and electrical connectivity, thus resolving the contradiction between contact reliability and height adaptability
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 design enhances the secure interlocking and electrical connectivity between busbars and battery cells, facilitating reliable weld operations and improved thermal management, thereby enhancing the performance and durability of vehicle traction batteries.
Implementation Method 1
The busbar spans between the cells and defines a pair of arms each having a trough member sized to sit within one of the valleys and a terminal aperture to receive one of the terminals
Implementation Method 2
The busbar electrically connects the terminals
Implementation Method 3
At least one of the terminal apertures may be spaced in between outer edges of the respective arms such that a first and second surface area provide space sufficient for weld spots on either side of the terminal aperture
Data Source
AI summary
A vehicle traction battery assembly including a pair of battery cells and a busbar is provided. Each of the battery cells may include a terminal and one or more locating features. The busbar may span between the cells and define a pair of arms each having a member sized to at least partially interlock with the one or more locating features. The busbar may span between the cells such that the busbar covers at least a portion of upper surfaces defined by each of the cells. At least one of the terminal apertures may be spaced in between outer edges of the respective arms such that a first and second surface area provide space sufficient for weld spots.