Flexible Busbar Assembly for Compact Battery Pack Sensing
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Solution Overview
Problem
Existing battery packs face challenges in achieving high energy density and cost-effectiveness, particularly in large-scale applications like electric vehicles, where the need for multiple batteries increases complexity and volume, while maintaining efficient voltage and temperature measurement.
Innovation Solution
A battery pack design featuring a busbar assembly with a flexible substrate and insulation films that electrically connect and measure battery cells, reducing the need for separate holders and minimizing volume, thereby enhancing energy density and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple separate batteries are used to increase output voltage and current for high-power applications, then the power output is improved, but the device complexity and volume increase
Solution Approach 1:
Multiple battery cells are electrically connected in series through a busbar assembly, merging their output to achieve high voltage and current. The busbar integrates multiple connection functions into a single component, reducing the number of separate connections needed while maintaining the power output of multiple cells.
Solution Approach 2:
The busbar assembly serves multiple functions simultaneously: it provides electrical connection between battery cells, supports the flexible substrate for sensing, and integrates insulation and structural support functions. This multi-functionality reduces the need for separate components and reduces overall system complexity.
2Power
If multiple separate batteries are used to increase output voltage and current for high-power applications, then the power output is improved, but the volume increases
Solution Approach 1:
The flexible substrate containing sensing circuits is embedded within or attached to the busbar assembly structure. The insulation films are positioned between and around the busbar and substrate components. This nesting arrangement allows multiple functional elements to occupy overlapping or adjacent spaces, reducing the total volume required for high-power battery configurations.
3Stability of the object's composition
If separate holders and support members are used to maintain battery cell connections, then the structural stability is improved, but the volume and device complexity increase
Solution Approach 1:
The busbar assembly merges the structural support function with the electrical connection function. The busbar itself serves as both the conductor for electrical current and the structural element that maintains the spatial arrangement of battery cell terminals, eliminating the need for separate holders and support members.
Solution Approach 2:
The busbar assembly provides multiple functions in a single component: electrical conduction, structural support, mechanical positioning of battery cells, and integration of sensing substrate. This multi-functionality reduces the number of separate components needed while maintaining structural stability.
4Quantity of substance
If insulation films and flexible substrate are integrated into the busbar assembly, then the energy density is improved, but the manufacturing complexity increases
Solution Approach 1:
The busbar assembly is constructed in layers with insulation films positioned between different components (busbar and flexible substrate). This segmented, modular structure allows each component to be manufactured separately and then assembled in a defined sequence, making the integration of multiple functions manageable while achieving high energy density.
Data Source
AI summary
A battery pack includes battery cells arranged in a first direction, and a busbar assembly coupled to upper portions of the battery cells, the busbar assembly having a busbar electrically connected to the battery cells, a flexible substrate configured to measure a state information of the battery cells, and an insulating film surrounding the busbar and the flexible substrate.