Integrated Busbar Terminal Layout for Low-Resistance Battery Packs
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Solution Overview
Problem
Existing battery packs in electrified vehicles face challenges in reliably connecting battery cells to achieve necessary voltage and power levels for propulsion, with issues related to packaging, temperature localization, and contact resistance at separate busbars and terminals.
Innovation Solution
An integrated busbar and terminal configuration is introduced, formed as a single piece without seams or joints, with specific bends and planes to facilitate smooth transitions and reduce contact resistance, using a stamping process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If separate busbars and terminals are used, then electrical connection is achieved, but packaging space is increased and contact resistance is elevated
Solution Approach 1:
The patent combines separate busbars and terminals into a single integrated component. The busbar includes an integrated terminal structure where the terminal is formed as one piece with the busbar body, eliminating the need for separate terminal components and reducing packaging space while maintaining electrical connection reliability through continuous conductive material.
Solution Approach 2:
The integrated busbar structure performs multiple functions: it serves as the current collector (busbar function), provides mechanical support, and incorporates the terminal connection interface all in one component. This multi-functional design reduces the number of parts and assembly steps while improving packaging efficiency.
2Temperature
If separate busbars and terminals are used, then electrical connection is established, but localized temperature increase occurs due to contact resistance
Solution Approach 1:
By integrating the terminal directly into the busbar as a single piece, the invention eliminates the contact interface between separate busbar and terminal components. This removes the contact resistance that causes localized heating, thereby reducing temperature increase at connection points while maintaining reliable electrical connection.
3Volume of moving object
If integrated busbar and terminal configuration is used, then packaging space is reduced and contact resistance is lowered, but manufacturing complexity increases
Solution Approach 1:
The integrated busbar and terminal are manufactured as a single piece using stamping processes. The design incorporates standard stamping operations including bending, forming, and punching that can be performed in sequence on a single workpiece, reducing the need for complex multi-step manufacturing or assembly processes.
Solution Approach 2:
The invention uses standard stamping parameters and forming techniques to create the integrated structure. By designing the terminal and busbar geometry to be compatible with conventional stamping processes, the manufacturing complexity is minimized while achieving the integrated configuration.
Data Source
AI summary
A battery pack may include an array of battery cells. A battery pack may include an integrated component including a busbar portion and a terminal portion. The busbar portion is arranged adjacent an end of the array of battery cells, and the terminal portion provides a terminal of the battery pack.