Inter-Pack Busbar Layout for Collision-Resistant Battery Modules
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Solution Overview
Problem
In power battery systems, high-voltage busbars arranged on both sides of the system battery module are prone to short-circuiting and damage during vehicle collisions, leading to system failure and loss of power.
Innovation Solution
The power battery system design includes busbars arranged within accommodating cavities between adjacent battery packs, rather than on the sides of the system battery module, to protect them from collision and extrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-voltage busbars are arranged on both sides of the system battery module, then the electrical connection between battery packs is achieved, but the busbars are prone to short-circuiting and damage during vehicle collisions
Solution Approach 1:
The busbar is extracted from the traditional side-wall arrangement and repositioned to be located between adjacent battery packs. This extraction from the vulnerable side position eliminates the busbar from the collision zone, preventing direct impact damage while maintaining its essential electrical connection function between battery packs.
Solution Approach 2:
The busbar arrangement transitions from a two-dimensional side-wall configuration to a three-dimensional inter-pack positioning. By moving the busbar into the space between battery packs (a different spatial dimension), the design achieves both protection from collision and maintained electrical connectivity.
2Ease of manufacture
If busbars are arranged on the side of the system battery module, then the electrical connection is simplified, but the system is vulnerable to collision and extrusion
Solution Approach 1:
The busbar is extracted from the side-wall arrangement and repositioned between battery packs. This extraction maintains manufacturing simplicity while simultaneously providing collision protection, as the busbar is now shielded by the battery pack structures on both sides.
Solution Approach 2:
The busbar installation is merged with the battery pack assembly process. By positioning the busbar between adjacent battery packs during assembly, the connection is achieved through the same manufacturing steps as the battery pack installation, maintaining ease of manufacture while improving collision resistance.
Data Source
AI summary
The present application provides a power battery system, which relates to the technical field of power batteries. By arranging the busbar on the battery pack in the accommodating cavity inside the system battery module, it improves the connection when the two sides of the system battery module are collided. The high-voltage busbar between the battery management system and the external interface of the system battery module and located on both inner side walls of the system battery module is short-circuited. The power battery system includes a battery case and a system battery module fixed inside the battery case. The system battery module includes a plurality of battery packs. Adjacent battery packs are spaced apart to form accommodating cavities and the busbar connected between the adjacent battery packs is located in the accommodating cavity.