Movable Busbar Assembly for Battery Pack Swelling Protection
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Solution Overview
Problem
Existing battery packs face issues with lead and tab damage due to swelling, leading to potential short circuits, fires, and reduced performance, as conventional solutions fail to provide sufficient movement for busbars during swelling.
Innovation Solution
A battery pack design with movable busbar frames and busbars that allow for movement towards the side plates, coupled with a cushion member to absorb expansion forces, preventing lead and tab damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If busbars are fixed rigidly to the pack case, then electrical connection stability is improved, but lead and tab damage occurs due to swelling
Solution Approach 1:
The busbar assembly is designed with movable connections that allow dynamic adjustment during battery swelling. The busbar can move relative to the pack case through controlled deformation of connection portions, maintaining electrical contact while accommodating volume changes of the battery cells.
Solution Approach 2:
The connection portion of the busbar is designed to change its physical state from rigid to flexible under swelling forces. The material or structural parameters of the connection portion allow it to deform elastically, changing its rigidity to absorb expansion forces while maintaining electrical conductivity.
2Object-affected harmful factors
If busbars are made movable to accommodate swelling, then lead and tab damage is prevented, but short circuit risk increases
Solution Approach 1:
The busbar connection structure acts as an intermediary element between the battery cells and the fixed pack case. It absorbs and redirects swelling forces through controlled deformation, preventing direct contact between swollen cells and adjacent leads while maintaining proper electrical isolation.
Solution Approach 2:
The movable busbar assembly extracts the swelling accommodation function from the rigid pack case structure. By isolating the movement capability in the busbar connection portions, the design prevents swelling forces from affecting other critical components like leads and tabs, thereby reducing short circuit risk.
3Ease of manufacture
If conventional fixed busbar assembly is used, then manufacturing simplicity is maintained, but swelling causes performance degradation
Solution Approach 1:
The busbar assembly is segmented into fixed portions and movable connection portions. This segmentation allows the majority of the busbar structure to remain simple and rigid for easy manufacturing, while specific connection sections incorporate flexibility to accommodate swelling without compromising overall performance.
Data Source
AI summary
A battery pack has a movable busbar assembly and a secondary battery including the same. More particularly, a battery pack has a movable busbar assembly configured such that at least one of a first busbar frame located at the front surface of a pack case, a second busbar frame located at the rear surface of the pack case, a first busbar connected to the first busbar frame, and a second busbar connected to the second busbar frame is movable in a direction toward a side plate of the pack case, whereby it is possible to minimize short circuit between leads, and a secondary battery including the same.