Floating Busbar Assembly for Battery Terminal Variation
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Solution Overview
Problem
Traction battery packs face challenges in accommodating build and part variations when connecting busbars directly to battery cell terminals, as existing solutions do not allow for adequate flexibility and secure retention within the pack.
Innovation Solution
A busbar module with a carrier frame and cap design that allows the busbars to float within pockets, secured by ledges and caps, enabling flexible positioning and secure retention while allowing for variations in terminal placement, and integrating with the battery pack enclosure for load distribution and venting channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If busbars are directly connected to battery cell terminals, then electrical connection is established, but flexibility to accommodate build and part variations is insufficient
Solution Approach 1:
The busbar assembly is segmented into modular components: a carrier frame with multiple pockets, individual busbars, and a cap. This segmentation allows each component to be optimized independently - the carrier frame provides structural support and positioning, while the busbars can float within pockets to accommodate variations in terminal placement, maintaining both adaptability and reliable retention.
Solution Approach 2:
The carrier frame acts as an intermediary between the battery cell terminals and the busbars. It provides a stable mounting structure with pockets that receive and position the busbars, while the cap secures the assembly. This intermediary structure decouples the direct connection requirement, allowing flexibility in accommodating build variations while ensuring secure retention through the carrier frame and cap mechanism.
2Reliability
If busbars are secured rigidly to accommodate terminal placement, then connection stability is improved, but adaptability to build variations is reduced
Solution Approach 1:
The busbar retention system incorporates dynamic characteristics by allowing the busbars to float within the pockets of the carrier frame. This floating capability enables the busbars to adjust their position dynamically to accommodate variations in terminal placement while maintaining stable electrical connections. The cap provides securing force, but the floating mechanism allows adaptive positioning for connection stability.
3Reliability
If multiple busbars are held securely, then retention reliability is improved, but device complexity increases
Solution Approach 1:
Multiple busbars are merged into a single integrated assembly using a common carrier frame and a single cap that secures all busbars simultaneously. This merging approach maintains reliable retention of multiple busbars while reducing overall complexity compared to using separate retention mechanisms for each busbar. The carrier frame with multiple pockets provides organized holding, and the single cap provides unified securing.
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
The solution provides a flexible and secure busbar retention system that accommodates variations in terminal placement, reduces part quantity, and facilitates higher battery cell density within the pack, ensuring reliable electrical connections and thermal management.
Implementation Method 1
the cap is secured to the carrier frame with at least one heat stake
Data Source
AI summary
A traction battery assembly includes a busbar, a carrier frame having a pocket that receives the busbar, and a cap secured to the carrier frame to contain the busbar within the pocket. A busbar retention method includes positioning at least one busbar with a pocket of a carrier frame and resting the busbar on at least one ledge and securing a cap to the carrier frame to hold the at least one busbar within the pocket.