Pouch Cell Bus Bar Assembly With Thin Sensing Bar for Higher Energy Density
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Solution Overview
Problem
Current battery assemblies face challenges in achieving high energy density, which is crucial for improving the driving efficiency and range of mobility applications.
Innovation Solution
The battery assembly incorporates a cell stack with pouch type battery cells and a first bus bar assembly that includes a sensing bar with a small thickness to measure electric potentials, replacing traditional bus bars to reduce mass and enhance energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional bus bars are used to measure electric potentials, then the structural strength and electrical conductivity are sufficient, but the mass increases and energy density decreases
Solution Approach 1:
The patent changes the thickness parameter of the sensing bar from traditional bus bar dimensions to a reduced thickness of 0.2mm-0.4mm. This parameter change maintains sufficient electrical conductivity for potential measurement while dramatically reducing the mass contribution of the sensing component, thereby improving energy density.
Solution Approach 2:
The patent applies different thickness specifications to different components: the sensing bar has a reduced thickness (0.2mm-0.4mm) optimized for measurement function, while the main bus bars maintain greater thickness (5-20 times the sensing bar thickness) for structural strength and current carrying capacity. This local differentiation optimizes both mass reduction and reliability.
2Quantity of substance
If the thickness of the sensing bar is reduced to improve energy density, then the mass decreases, but the structural strength and measurement capability may be compromised
Solution Approach 1:
The patent optimizes the thickness parameter to a specific range (0.2mm-0.4mm) that balances structural integrity with mass reduction. This parameter optimization ensures the sensing bar maintains sufficient strength for its measurement function while contributing minimally to overall mass, thereby improving energy density without sacrificing reliability.
Solution Approach 2:
The sensing bar is designed with localized thickness optimization - thin enough to reduce mass and improve energy density, but sufficiently thick in critical areas to maintain structural strength and electrical contact capability. The main bus bars retain greater thickness for overall structural support.
3Stability of the object's composition
If a module frame is included in the battery assembly, then the structural stability is improved, but the mass increases and energy density decreases
Solution Approach 1:
The patent extracts and removes the module frame component from the battery assembly structure. By eliminating this non-essential structural element, the overall mass of the battery assembly is reduced, directly improving energy density while maintaining necessary structural stability through alternative design approaches.
Solution Approach 2:
The bus bar assembly is designed to perform multiple functions: electrical connection, potential measurement, and partial structural support. This multi-functionality allows the sensing bar and bus bars to compensate for the removed module frame, maintaining structural stability without the additional mass of a dedicated frame structure.
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 improves the energy density of the battery assembly by reducing its mass while maintaining effective voltage output and safety features, thereby enhancing the performance and range of mobility applications.
Implementation Method 1
a first sensing bar configured to measure electric potentials of the second negative electrode lead and the third positive electrode lead
Data Source
AI summary
Provided is a battery assembly according to example embodiments. The battery assembly includes a cell stack with first to third pouch type battery cells, and a first bus bar assembly. The first bus bar assembly includes a first bus bar, a second bus bar, and a first integrated circuit including a first sensing bar configured to measure electric potentials of a second negative electrode lead of the second pouch type battery cell and a third positive electrode lead of the third pouch type battery cell. A thickness of the first sensing bar is less than a thickness of the first bus bar.