Integrated Bus Bar and Shunt for Vehicle Battery
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Solution Overview
Problem
Traditional automotive battery systems require complex and costly designs with fluid-filled containers, additional structural components, and multiple sealing steps, which can lead to inefficiencies and safety concerns, especially in electric vehicles where high voltage batteries need to be integrated with low voltage systems.
Innovation Solution
A battery monitoring system with an integrated bus bar and printed circuit board (PCB) configuration that secures a shunt to monitor current, eliminating the need for fluid-filled containers and reducing manufacturing complexity by using a single piece of electrically conductive material for the bus bar and shunt, and integrating structural components within the housing to minimize external protective structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fluid-filled container designs are used, then structural protection is provided, but manufacturing complexity and cost increase
Solution Approach 1:
The bus bar and shunt are merged into a single integrated component formed from one piece of electrically conductive material. This eliminates the need for separate structural containers and multiple sealing steps, reducing manufacturing complexity while maintaining the protective function through the integrated design.
Solution Approach 2:
The bus bar serves multiple functions: it provides electrical current conduction, acts as a structural support element, and integrates the shunt for current monitoring. This multi-functionality eliminates the need for separate fluid-filled containers and additional structural components, simplifying manufacturing while maintaining reliability.
2Reliability
If multiple separate components are used for bus bar and shunt, then electrical functionality is achieved, but weight and manufacturing cost increase
Solution Approach 1:
The bus bar and shunt are combined into a single integrated component formed from one piece of electrically conductive material. This reduces the total weight by eliminating separate components, fasteners, and connection points while maintaining all necessary electrical functions including current conduction and monitoring.
3Reliability
If complex sealing structures are used, then safety is improved, but manufacturing time and cost increase
Solution Approach 1:
The integrated bus bar-shunt design eliminates the need for multiple sealing steps and separate protective structures. The single-piece construction inherently provides safety by preventing short circuits while simplifying manufacturing to a single assembly operation, significantly improving productivity.
4Ease of manufacture
If integrated bus bar with shunt is used, then manufacturing is simplified, but electrical connection precision must be maintained
Solution Approach 1:
The bus bar and shunt are formed as a single integrated piece, which inherently maintains precise electrical connections by eliminating separate connection points and fasteners. The integrated design ensures consistent electrical pathways while simplifying manufacturing to a single forming operation, simultaneously achieving ease of manufacture and manufacturing precision.
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 simplifies manufacturing, reduces weight and cost, enhances safety by preventing short circuits, and maintains optimal environmental conditions for electrochemical cells, improving the reliability and efficiency of battery systems in electric vehicles.
Implementation Method 1
The shunt may include two transverse extensions of the bus bar. The shunt and the bus bar may be formed of a single contiguous piece of electrically conductive material.
Data Source
AI summary
Disclosed herein are battery systems for electric vehicles. An electric vehicle may include a first battery. The first battery may be configured to power various low voltage systems. For example, the first battery may provide the power to start the vehicle. The vehicle may include a second battery. The second battery may be configured to power one or more electric motors for propelling the vehicle. The first battery may include a housing. The housing may include a battery monitoring system. The battery monitoring system may include a PCB that is secured to at least one bus bar. The bus bar may include an integrated shunt. The shunt may be coupled to circuitry on the PCB that is configured to monitor current.