Layered Bus Bar Structure for Durable Battery Pack Connections
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Solution Overview
Problem
Existing battery packs face challenges in ensuring the durability of bus bars while maintaining strong connections with battery cells and other components.
Innovation Solution
The battery pack incorporates a bus bar with a single-layer and multi-layer portion, where the single-layer portion includes a first material layer, and the multi-layer portion includes a continuous first material layer and a second material layer formed on its surfaces, ensuring strong homogeneous metal bonds at different connection positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single-layer bus bar structure is used, then the manufacturing process is simple, but the connection strength and durability at different connection positions are insufficient
Solution Approach 1:
The bus bar employs different layer structures at different locations: a single-layer structure at the first connection position (battery cell terminal) and a multi-layer structure at the second connection position (circuit board). This local differentiation optimizes connection strength where needed while maintaining manufacturing simplicity where possible.
Solution Approach 2:
The bus bar uses composite material layers including a first material layer (aluminum or aluminum alloy) and a second material layer (copper or copper alloy) with different electrical and mechanical properties. The first material layer provides lightweight conductivity while the second material layer enhances connection strength and corrosion resistance at critical interfaces.
2Reliability
If a multi-layer bus bar structure is used throughout, then the connection strength and durability are improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The multi-layer structure is applied selectively only at the second connection position where high reliability is critical for circuit board connections, while the first connection position uses a simpler single-layer structure. This localized approach improves durability where needed without unnecessarily complicating the entire bus bar manufacturing process.
3Stability of the object's composition
If the first material layer is discontinuous between single-layer and multi-layer portions, then manufacturing is easier, but the bond homogeneity and electrical conductivity are reduced
Solution Approach 1:
The first material layer is designed to be continuous between the single-layer and multi-layer portions of the bus bar, creating a unified structural backbone that ensures homogeneous metal bonds and consistent electrical conductivity throughout the entire component while accommodating local structural variations.
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
Disclosed is a battery pack. The battery pack includes a plurality of battery cells and a bus bar electrically connected to the plurality of battery cells. The bus bar includes a single-layer portion and a multi-layer portion which have different numbers of stacks in the thickness direction. The single-layer portion includes a first material layer, and the multi-layer portion includes a first material layer continuously connected from the first material layer of the single-layer portion and a second material layer formed on at least one of a surface or a rear surface of the first material layer. The battery pack according to the disclosure may include the bus bar which has an improved structure to ensure durability of the bus bar while forming a strong homogeneous metal bond with an object to be connected.