Modular Busbar Module for Traction Battery Assembly

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing traction battery assemblies face challenges in efficiently connecting and managing the electrical connections between battery cells due to rigid busbar frames that are not modular, leading to increased tooling costs and reduced flexibility in accommodating varying cell array configurations.

Innovation Solution

The use of modular busbar modules composed of separately formed end pieces and a center piece, interconnected by connection features such as dovetail connections or pegs, allows for flexible assembly and secure electrical connections between terminals and busbars, accommodating different cell array lengths and configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If rigid busbar frames are used, then structural strength is improved, but manufacturing flexibility and adaptability to varying cell array configurations deteriorate

Engineering Contradiction:

Improvestructural strengthVSAvoidflexibility in accommodating varying cell array configurations

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The busbar frame is divided into multiple separate busbar modules that can be independently formed and then assembled together. Each module can be customized for different cell array configurations, while the modular design maintains overall structural strength through standardized connection features between modules.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If modular busbar modules are used, then adaptability to varying cell array configurations is improved, but device complexity increases

Engineering Contradiction:

Improveadaptability to varying cell array configurationsVSAvoidcomplexity of busbar assembly

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The busbar modules incorporate universal connection features that can interface with different cell array configurations using the same standardized interface. This multi-functionality allows a single module design to serve multiple purposes across various battery pack sizes and layouts, reducing overall system complexity despite the modular approach.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If separately formed busbar modules are used, then tooling costs are reduced, but connection reliability between modules may deteriorate

Engineering Contradiction:

Improvetooling costsVSAvoidconnection reliability between modules

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The busbar modules are designed with complementary connection features that mechanically interlock and electrically connect when assembled. The combination of modules creates a unified structure with reliable connections, while each individual module can be manufactured using simpler, less expensive tooling compared to a single large rigid frame.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS10431803B2Traction battery assembly having multipiece busbar module

Publication Date: 2019.10.01 FORD GLOBAL TECH LLC

AI summary

A traction battery includes cells stacked in an array and having terminals, and endplates sandwiching the array. A busbar module extends between the endplates and includes slots and busbars interleaved along a length of the busbar module. The terminals extend through the slots and connect to the busbars. The busbar module includes a pair of end pieces and a center piece that are separately formed and secured together by connection features.