Structural Foam Busbar Carrier for Large Battery Pack Assembly
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Solution Overview
Problem
The assembly of large battery packs for electric vehicles is time-consuming and costly due to the need for numerous parts and the limitations of conventional injection molding processes, which restricts the size of injection molded carriers and increases production costs and cycle times.
Innovation Solution
A busbar interconnect system using structural foam elements arranged in a matrix to hold busbars in place, reducing the number of parts and enabling efficient electrical connection of battery cells, with a molded body formed around the busbars to maintain their relative positions and support them structurally.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional injection molding processes are used to create busbar carriers, then the carriers can be manufactured with integrated busbar positioning, but the size of the carrier is limited and production cycle time increases
Solution Approach 1:
The busbar carrier is divided into multiple modular sections that can be manufactured separately using conventional injection molding processes. Each module contains positioned busbars and can be assembled with other modules to create carriers of any required size, eliminating the size limitations of single-piece molding while maintaining integrated busbar positioning benefits.
2Ease of manufacture
If conventional injection molding processes are used to create busbar carriers, then the carriers can be manufactured with integrated busbar positioning, but production cycle time increases
Solution Approach 1:
The carrier is segmented into multiple modules that can be manufactured in parallel using multiple injection molding machines. This modular approach reduces the cycle time per unit while maintaining the integrated positioning benefits, as each module can be produced independently and simultaneously.
Solution Approach 2:
Busbars are pre-positioned and secured within each modular section before the injection molding process begins. This preliminary action eliminates the need for complex in-mold busbar positioning mechanisms, reducing cycle time while maintaining precise busbar positioning in the final assembled carrier.
3Adaptability or versatility
If numerous individual parts are used to assemble battery systems, then flexibility in design is maintained, but assembly time and cost increase
Solution Approach 1:
Multiple individual busbar components and their positioning structures are merged into integrated modular carrier sections. These modules can be assembled together in few steps to create complete busbar carriers for various battery pack configurations, reducing assembly time while maintaining design flexibility through modular combinations.
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 solution streamlines the assembly process, reduces part count, and enhances durability by providing a high strength-to-weight ratio, allowing for larger battery pack sizes while minimizing capital and conversion costs, and promoting sustainable manufacturing practices.
Implementation Method 1
The molded body includes frame members holding corresponding busbars. The frame members are structural foam elements.
Data Source
AI summary
A busbar interconnect for electrically connecting cell terminals of battery cells in a battery pack includes a matrix of busbars. Each busbar includes a first mating end for mating with the corresponding cell terminal of the corresponding battery cell and a second mating end for mating with the adjacent cell terminal of the adjacent corresponding battery cell. The busbars electrically connect the battery cells in the battery pack. The busbar interconnect includes a busbar carrier holding each of busbars in the matrix. The busbar carrier includes a molded body formed around each of the busbars holding relative positions of the busbars. The molded body includes frame members holding corresponding busbars. The frame members are structural foam elements.