Flexible Busbar Connection for Battery Stack Misalignment
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Solution Overview
Problem
Existing electrical connection systems in traction battery packs face challenges in accommodating misalignment and build tolerances between battery cell stacks, leading to difficulties in secure and efficient electrical connections.
Innovation Solution
The proposed electrical connection system includes a flexible first busbar with multiple bends and a rigid second busbar, joined by a mechanical fastener, allowing for vertical and horizontal flexing to align and secure the contacts, even in the presence of misalignment, using oval-shaped apertures to facilitate secure fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid electrical contacts are used to ensure stable electrical connection, then connection stability is improved, but ability to accommodate misalignment and build tolerances deteriorates
Solution Approach 1:
The electrical connection system employs a hybrid dynamic structure where the first electrical contact is configured to flex relative to both the second electrical contact and the first electrical contact itself. This dynamic flexibility allows the rigid electrical contacts to maintain stable electrical connection while accommodating misalignment and build tolerances through controlled flexing motion.
Solution Approach 2:
The system segments the electrical contact into two distinct parts: a flexible first electrical contact and a rigid second electrical contact. This segmentation allows each component to serve its specific function - the flexible part absorbs misalignment and tolerances, while the rigid part ensures stable electrical connection.
2Adaptability or versatility
If flexible electrical contacts are used to accommodate misalignment, then adaptability is improved, but connection stability deteriorates
Solution Approach 1:
The system employs a hybrid dynamic structure where the first electrical contact is configured to flex relative to both the second electrical contact and the first electrical contact itself. This dynamic flexibility allows the rigid electrical contacts to maintain stable electrical connection while accommodating misalignment and build tolerances through controlled flexing motion.
3Adaptability or versatility
If multiple bends are added to the first electrical contact to increase flexibility, then adaptability is improved, but manufacturing complexity increases
Solution Approach 1:
The system applies local quality by concentrating the flexibility requirement specifically in the first electrical contact that interfaces with the battery terminal, while keeping the second electrical contact rigid. The multiple bends are strategically positioned in the first contact to provide localized flexibility where needed, without unnecessarily complicating the entire connection system.
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 enables reliable and efficient electrical connections within traction battery packs by accommodating misalignment and build tolerances, ensuring secure and efficient power transfer between battery cell stacks.
Implementation Method 1
the first electrical contact configured to flex relative to the second electrical contact along a first axis, and configured to flex relative to the first electrical contact along a second axis
Data Source
AI summary
An electrical connection system includes a first electrical contact, and a second electrical contact joined directly to the first electrical contact. The first electrical contact is configured to flex relative to the second electrical contact along a first axis, and configured to flex relative to the first electrical contact along a second axis.