Battery Pack Bus Bar Layout for High-Voltage Short Risk Reduction
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Solution Overview
Problem
Existing battery packs face challenges in efficiently managing voltage differences between cells, leading to potential electrical shorts and safety risks, particularly in high-voltage configurations like the 72-cell structure, where maximum potential differences can exceed 200V, compromising safety and reliability.
Innovation Solution
The battery pack design incorporates a zigzag configuration for bus bars and electrical connections, reducing potential differences between adjacent cells by alternating the arrangement of cells and bus bars, and using a circuit board with specific opening regions to expose protruding connection pieces and cooling flow paths, thereby minimizing electrical interference and enhancing safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple battery cells are connected in series to increase output voltage and capacity for high-power applications, then the power output capability is improved, but the voltage difference between cells increases leading to electrical short risks and safety issues
Solution Approach 1:
The battery pack is divided into multiple independent battery cells, each with its own protective casing and terminal structure. This segmentation allows individual cell management while maintaining overall system power through series connection, addressing the contradiction by enabling high power output while isolating voltage differences at the cell level
Solution Approach 2:
A circuit board is introduced as an intermediary component between battery cells, providing electrical connection and management functions. The circuit board includes opening regions that expose protruding connection pieces, facilitating controlled electrical connections while managing voltage differences between cells in series configurations
2Power
If a 72-cell series configuration is used to achieve high voltage output, then the energy density and power capability are improved, but the potential difference between cells exceeds 200V creating electrical short hazards
Solution Approach 1:
The 72-cell battery pack is segmented into multiple modules or groups, with each group managed independently through the circuit board structure. This segmentation reduces the voltage differential impact on any single connection point, mitigating electrical short risks while maintaining overall high voltage output capability
Solution Approach 2:
The circuit board acts as an intermediary management system that distributes and manages electrical connections across 72 cells. The opening regions and protruding connection pieces provide controlled connection points that prevent direct exposure to high voltage differences, reducing electrical short hazards while enabling high voltage operation
3Productivity
If bus bars are used to electrically connect battery cells in series, then the electrical connection efficiency is improved, but the concentration of high voltage differences at connection points increases safety risks
Solution Approach 1:
The electrical connection system is segmented into multiple connection points distributed across the circuit board rather than concentrated at single bus bar locations. This segmentation distributes voltage stress across multiple isolated points, maintaining connection efficiency while improving safety
Solution Approach 2:
The circuit board with opening regions and protruding connection pieces serves as an intermediary between bus bars and battery terminals. This intermediary structure provides controlled connection geometry that maintains electrical efficiency while managing and distributing voltage differences to reduce safety risks
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 design reduces the risk of electrical shorts and enhances safety by minimizing voltage differences between cells, ensuring reliable operation even in high-voltage configurations, such as the 72-cell structure, while maintaining a compact and efficient energy density.
Implementation Method 1
an adhesive resin on the battery cells at positions corresponding to edge portions surrounding the central portions of the upper end portions or the lower end portions of the battery cells
Implementation Method 2
The potting resin may cover coupling structures between the bus bars and the upper end portions or the lower end portions of the battery cells
Data Source
AI summary
A battery pack including battery cells; a potting resin on the battery cells at positions corresponding to central portions of upper end portions or lower end portions of the battery cells in a height direction of the battery cells; and an adhesive resin on the battery cells at positions corresponding to edge portions surrounding the central portions of the upper end portions or the lower end portions of the battery cells.