Internal Busbar Battery Pack Housing Design
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Solution Overview
Problem
The manufacturing of electric vehicle battery systems faces challenges in ensuring reliable electrical connections, efficient cooling, and cost-effective assembly of thousands of individual battery cells into modular systems that can be easily installed and replaced.
Innovation Solution
A battery pack design featuring internal busbars with indentations to support and orient battery cells, along with a cooling duct for heat removal, providing both electrical and thermal conductivity, and a method for manufacturing that includes attaching busbars to trays and arranging cooling ducts between cells to facilitate parallel and serial connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional external busbar connections are used, then electrical connections between battery cells can be established, but manufacturing complexity and assembly time increase
Solution Approach 1:
The busbar is integrated directly into the housing structure, merging the electrical connection function with the structural support function. This eliminates separate external busbar components and their associated assembly steps, thereby reducing manufacturing complexity while maintaining reliable electrical connections between battery cells.
Solution Approach 2:
The housing structure serves multiple functions: it provides mechanical support, thermal management pathways, and electrical connections through the integrated busbar. This multi-functionality reduces the total number of components needed and simplifies the overall manufacturing process while ensuring reliable electrical connectivity.
2Reliability
If thousands of individual battery cells are assembled into modular systems, then system reliability and serviceability improve, but assembly time and manufacturing cost increase
Solution Approach 1:
The battery system is divided into modular units with standardized housing structures that can be independently assembled and replaced. The integrated busbar design within each housing module allows for quick connection and disconnection, enabling rapid assembly and replacement of modular battery systems while maintaining high reliability.
Solution Approach 2:
The busbars are pre-integrated into the housing structures during manufacturing, so that when modules are assembled, electrical connections are automatically established without requiring separate connection steps. This preliminary integration significantly reduces assembly time while maintaining system reliability.
3Temperature
If cooling ducts are added to remove heat from battery cells, then thermal management and battery service life improve, but device complexity and manufacturing cost increase
Solution Approach 1:
The cooling ducts are integrated directly into the housing structure, merging the thermal management function with the structural support function. This eliminates the need for separate external cooling systems and reduces overall device complexity while effectively removing heat from battery cells to extend service life.
4Reliability
If internal busbars with indentations are used to support battery cells, then electrical connection reliability and cell orientation precision improve, but manufacturing precision requirements increase
Solution Approach 1:
The housing structure features localized indentations at specific positions where battery cells need to be supported and connected. These localized features concentrate the precision requirements to specific areas rather than the entire structure, making the manufacturing precision requirements more manageable while ensuring reliable electrical connections at critical points.
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 enhances the reliability and safety of battery systems by ensuring efficient electrical connections and effective heat management, reducing manufacturing costs and improving the service life of battery systems while allowing for easier assembly and replacement.
Implementation Method 1
a cooling duct running between adjacent battery cells, where the cooling duct is configured to remove heat from the plurality of battery cells
Implementation Method 2
the cooling duct is configured to remove heat from the plurality of battery cells
Implementation Method 3
a first busbar attached to the upper tray... a second busbar attached to the lower tray... The first and second busbars are electrically connected to the battery cells
Data Source
AI summary
A battery pack for an electric vehicle is disclosed. The battery pack includes an upper tray, a first busbar attached to the upper tray, a lower tray, and a second busbar attached to the lower tray. The battery pack also includes a plurality of battery cells arranged in the upper and lower trays between the first and second busbars, where the first busbar is between the battery cells and the upper tray, and where the second busbar is between the battery cells and the lower tray.