Multipiece Busbar Module With Pivoting Flaps for Battery Terminals
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Solution Overview
Problem
Existing traction battery assemblies for motor vehicles face challenges in efficiently connecting and mechanically joining busbars to terminals in a way that ensures reliable electrical interconnection and thermal management, particularly in high-voltage systems.
Innovation Solution
The use of busbars with pivotally attached flaps and a curved terminal design, where the curved portion of the terminal is in contact with the flaps, provides a secure mechanical and electrical connection, allowing for effective thermal management and efficient energy transfer between battery cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-piece busbar design is used, then the manufacturing process is simpler, but the adaptability to different terminal configurations and packaging constraints is reduced
Solution Approach 1:
The busbar is divided into multiple separable pieces with connecting portions that can be assembled together. Each busbar piece can be independently manufactured with standard configurations, then joined via the connecting portions to accommodate various terminal arrangements and packaging constraints in different vehicle applications.
2Reliability
If a rigid fixed connection is used between busbar and terminal, then the electrical connection is stable, but the thermal management efficiency is reduced
Solution Approach 1:
The connecting portion incorporates movable flaps that can pivot relative to the busbar body. These flaps are biased by springs to maintain contact with terminals, providing both electrical connection stability through continuous contact and thermal management efficiency by allowing dynamic adjustment to accommodate thermal expansion and contraction during battery operation.
3Adaptability or versatility
If complex multi-component busbar assembly is used, then the adaptability to packaging constraints is improved, but the device complexity increases
Solution Approach 1:
The connecting portion serves multiple functions simultaneously: it provides electrical connection between busbar pieces and terminals, enables mechanical attachment through flap pivoting, facilitates thermal management through dynamic contact adjustment, and allows adaptability to different packaging constraints. This multi-functionality reduces the need for separate specialized components for each function.
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 configuration enhances the reliability and efficiency of energy transfer within the traction battery assembly, improving the overall performance and durability of the battery system while accommodating various vehicle power requirements and packaging constraints.
Implementation Method 1
The terminal is mechanically joined to the connecting portion with the curved portion of the terminal in contact with at least one of the flaps
Implementation Method 2
busbars electrically interconnecting the cells
Data Source
AI summary
A traction battery includes a battery array having a stack of cells, wherein a first of the cells includes a terminal having a projecting portion extending from a body of the cell and a curved portion disposed on a distal end of the projecting portion. A busbar has a connecting portion defining a slot with a pair of first opposing sides and a pair of second opposing sides. The connecting portion further has a pair of flaps, each pivotally attached to one of the second opposing sides such that the flaps oppose each other. The terminal is mechanically joined to the connecting portion with the curved portion of the terminal in contact with at least one of the flaps.