Integrated Busbar Assembly for Compact Battery Pack Cooling
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Solution Overview
Problem
Conventional battery packs have increased manufacturing costs, complex assembly processes, reduced price competitiveness, lower energy density, and compromised cooling performance due to their complex cell frame structure.
Innovation Solution
A busbar assembly is introduced, featuring a sub-busbar for electrical connection to battery cell electrodes and a busbar cover with holes for guiding connections, along with a filling member to cover the busbar assembly and enhance thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a cell frame structure including an assembly of a plurality of plates is used, then the strength and stability of the battery pack are improved, but the manufacturing cost increases and the assembly process becomes complex
Solution Approach 1:
The busbar assembly integrates the cell frame structure with the busbar function by combining support plates and busbars into a single integrated component. This merging eliminates the need for separate cell frame plates while maintaining structural strength and providing electrical connection functions simultaneously.
Solution Approach 2:
The busbar assembly serves multiple functions: it provides structural support for the battery cells, establishes electrical connections between cells, and acts as a structural framework. This multi-functionality replaces the conventional separate cell frame structure, reducing assembly complexity while maintaining strength.
2Stability of the object's composition
If a cell frame structure including an assembly of a plurality of plates is used, then the structural stability is improved, but the manufacturing cost increases
Solution Approach 1:
The busbar assembly merges the structural support function with the electrical connection function into a single component. This reduces the number of parts that need to be manufactured and assembled, thereby lowering manufacturing costs while maintaining structural stability through the integrated design.
Solution Approach 2:
The busbar assembly utilizes composite construction combining conductive materials for electrical connection with structural materials for support. This composite approach optimizes both structural stability and manufacturing efficiency by selecting materials that fulfill multiple requirements simultaneously.
3Strength
If a cell frame structure including an assembly of a plurality of plates is used, then the strength is improved, but the total size increases and energy density decreases
Solution Approach 1:
The busbar assembly combines the cell frame structure with the busbar components, eliminating the need for separate external cell frame plates. This integration reduces the overall volume occupied by structural components while maintaining the necessary structural strength through the combined design.
Solution Approach 2:
The busbar assembly utilizes the vertical dimension by positioning busbars above and below the battery cells, allowing structural support and electrical connection functions to be achieved within the existing footprint without increasing the horizontal dimensions of the battery pack.
4Reliability
If a conventional busbar assembly structure is used, then the electrical connection is established, but the cooling performance is compromised
Solution Approach 1:
The busbar assembly is segmented into multiple components including upper and lower busbars, support plates, and spacers that can be independently positioned. This segmentation allows coolant channels to be integrated between these components, enabling thermal management while maintaining electrical connection reliability through the modular structure.
Data Source
AI summary
A battery pack according to an embodiment of the present disclosure includes a plurality of battery cells; and a busbar assembly positioned on a side of the battery cells and configured to electrically connect the battery cells, wherein the busbar assembly includes a sub-busbar for electrical connection to positive electrodes and negative electrodes of the battery cells; and a busbar cover configured to cover the sub-busbar, and having a busbar hole to guide the electrical connection between the sub-busbar and the battery cells.