Two-Piece Busbar Assembly for Low-Waste EV Battery Connections
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Solution Overview
Problem
Existing busbar assemblies for electrified vehicles are inefficient in material usage, leading to increased costs due to excessive material waste during manufacturing.
Innovation Solution
A two-piece busbar assembly comprising a first and second busbar component, formed using a single cutting process from a blank of material, where the components are identically sized and shaped, with feeders projecting from carriers and tabs connecting them, reducing material waste and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a one-piece busbar is used to connect battery cell terminals, then electrical connectivity is maintained, but material waste increases and manufacturing costs increase
Solution Approach 1:
The busbar is divided into multiple separate components (first busbar component and second busbar component) that can be formed from a single blank of material through a single cutting process. Each component has a carrier and feeders, and they are joined through tabs to form the complete busbar assembly, reducing material waste while maintaining functionality.
Solution Approach 2:
The first and second busbar components are combined through tabs that connect corresponding feeders from each component. The tabs are welded to the feeders, merging the two separate components into a functional busbar assembly that achieves the same electrical connectivity as a one-piece busbar with reduced material waste.
2Loss of substance
If a two-piece busbar assembly is used, then material waste is reduced, but manufacturing complexity increases
Solution Approach 1:
The busbar is segmented into two components formed from a single blank of material using a single cutting process. This segmentation allows for optimized material usage and reduced waste while the components are designed to be assembled through simple tab connections.
Solution Approach 2:
The tabs are formed as integral parts of the busbar components during the single cutting process, and they automatically align and connect corresponding feeders when the components are assembled. The structure is designed to self-align and self-connect, reducing the complexity of the manufacturing and assembly processes.
3Reliability
If feeders of first and second busbar components are spaced apart, then electrical connectivity is maintained, but manufacturing precision requirements increase
Solution Approach 1:
Tabs serve as intermediary elements that connect corresponding feeders from the first and second busbar components. The tabs are welded to the feeders and provide a reliable electrical connection while accommodating the spaced-apart configuration of the feeders, ensuring electrical connectivity without requiring extreme manufacturing precision.
Solution Approach 2:
The busbar is segmented into two components with feeders spaced apart, allowing each component to be formed with standard manufacturing tolerances. The segmentation enables the use of tabs as connection elements that bridge the gap between feeders, maintaining electrical connectivity while relaxing precision requirements compared to a one-piece design.
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
The two-piece busbar assembly significantly reduces material waste and manufacturing costs while maintaining effective electrical connectivity between battery cells, enhancing the efficiency and cost-effectiveness of electrified vehicle powertrains.
Implementation Method 1
the tabs are welded to the feeders of the first busbar component and the second busbar component
Data Source
AI summary
A battery assembly according to a non-limiting aspect of the present disclosure includes, among other things, an array of battery cells, with each cell including a terminal, and a busbar assembly having a first busbar component and a second busbar component. Further, each of the terminals are electrically coupled to both the first busbar component and the second busbar component. A method of forming a busbar assembly is also disclosed.