Flexible Composite Busbar Layout for CTP Battery Pack Reliability
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Solution Overview
Problem
The Cell to Pack (CTP) architecture of new energy vehicle battery packs faces challenges in impact resistance and control reliability due to their compact design and limited internal space.
Innovation Solution
The battery pack design incorporates a flexible composite busbar connected directly to the cells, a battery energy distribution module, a control module, and separate high-voltage and low-voltage circuits, which enhances impact resistance and control reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If CTP architecture is adopted to improve energy density, then the battery pack becomes more compact and integrated, but impact resistance and control reliability deteriorate due to limited internal space and compact structure
Solution Approach 1:
The patent divides the battery pack into distinct functional zones: a first area containing high-voltage circuits and components, and a second area containing low-voltage circuits and components. This spatial segmentation isolates high-voltage elements from low-voltage control systems, preventing interference and improving control reliability while maintaining the compact CTP architecture.
Solution Approach 2:
The patent introduces an isolated island structure as an intermediary element between high-voltage and low-voltage circuits. This isolated island provides electromagnetic shielding and physical separation, acting as a mediator that prevents high-voltage interference from affecting low-voltage control systems, thereby enhancing control reliability without compromising energy density.
2Device complexity
If high-voltage and low-voltage circuits are arranged together in compact space, then device complexity is reduced, but electromagnetic interference increases affecting control reliability
Solution Approach 1:
The patent segments the circuit arrangement into distinct high-voltage and low-voltage areas within the battery pack. By physically separating these circuits into different spatial zones, the patent reduces electromagnetic interference between them, improving control reliability while maintaining relatively simple overall device complexity through integrated pack design.
Solution Approach 2:
The patent applies different spatial arrangement strategies to different circuit types: high-voltage circuits are arranged in a first area with specific spacing and shielding, while low-voltage circuits are arranged in a second area with different spacing requirements. This local differentiation optimizes electromagnetic compatibility for each circuit type without requiring complete redesign of the entire system.
3Productivity
If cells are directly integrated into battery pack without modules, then assembly steps are omitted and manufacturing efficiency improves, but production error absorption capability deteriorates
Solution Approach 1:
The patent employs flexible busbars with dynamic adjustment capabilities to connect cells directly in the CTP architecture. These flexible busbars can deform and adapt to position variations, providing a dynamic compensation mechanism that absorbs manufacturing errors and assembly tolerances, thereby maintaining production efficiency while improving error absorption capability.
Solution Approach 2:
The patent utilizes flexible busbars whose physical parameters (such as bendability and position) can change to accommodate manufacturing variations. By allowing the busbar position and shape to adjust within certain ranges, the system absorbs production errors without requiring precise manufacturing tolerances, maintaining high assembly efficiency while compensating for variability.
Data Source
AI summary
Provided are a battery pack and an electric vehicle. The battery pack includes multiple cells, a flexible composite busbar, a battery energy distribution module, a control module, and an external interface. The flexible composite busbar is connected to the cells. The battery energy distribution module is connected to the flexible composite busbar. The control module is connected to the battery energy distribution module and configured to control the battery energy distribution module to be disconnected. The external interface is connected to the control module and configured to be connected to an external circuit. A circuit for connecting the battery energy distribution module to the external interface is configured to be a high-voltage circuit, a circuit for connecting the control module to the external interface is configured to be a low-voltage circuit, and the low-voltage circuit and the high-voltage circuit are arranged separately.