Integrated busbar and battery connection for electric vehicle battery packs
View Patent ↗A battery pack for an electric vehicle may include a plurality of battery cells arranged into one or more rows. Each of the plurality of battery cells may include a first terminal and a second terminal, and the plurality of battery cells may include a subset of battery cells with the first terminal oriented in a same direction in the battery pack. The battery pack may also include a busbar configured to conduct electrical energy to and from at least the subset of battery cells. The busbar may include a plurality of cutouts positioned over the first terminals of the subset of battery cells, and a plurality of tabs that springably contact the respective first terminal. A method of building a battery pack with a busbar connection is also presented.
1. A battery pack for an electric vehicle, the battery pack comprising:
a plurality of battery cells arranged into one or more rows, wherein:
each of the plurality of battery cells comprises a first terminal and a second terminal; and
the plurality of battery cells comprises a subset of battery cells with the first terminal oriented in a same direction in the battery pack; and
a busbar configured to conduct electrical energy to and from at least the subset of battery cells, the busbar comprising:
a plurality of cutouts positioned over the first terminals of the subset of battery cells; and
a plurality of tabs that springably contact the respective first terminal, wherein the plurality of cutouts are formed by punching holes with a tab in a metal sheet and thinning the tab.
2. The battery pack of claim 1 , wherein each of the plurality of tabs are less than 1.0 mm thick.
3. The battery pack of claim 1 , wherein the busbar comprises a metal sheet.
4. The battery pack of claim 1 , wherein the plurality of cutouts are arranged into one or more rows.
5. The battery pack of claim 1 , wherein the plurality of cutouts are further formed by bending the thinned tab into a springable profile.
6. The battery pack of claim 1 , wherein the busbar is positioned on a bottom plane of the battery pack.
7. The battery pack of claim 1 , wherein the busbar is more than 1.00 mm thick.
8. The battery pack of claim 1 , further comprising a second busbar positioned on a top plane of the battery pack and in contact with the second terminal of the subset of battery cells.
9. A method of manufacturing a battery pack for an electric vehicle, the method comprising:
arranging a plurality of battery cells into one or more rows, wherein:
each of the plurality of battery cells comprises a first terminal and a second terminal; and
the plurality of battery cells comprises a subset of battery cells with the first terminal oriented in a same direction in the battery pack; and
positioning a busbar configured to conduct electrical energy to and from at least the subset of battery cells, the busbar comprising:
a plurality of cutouts positioned over the first terminals of the subset of battery cells; and
a plurality of tabs that springably contact the respective first terminals of the subset of battery cells, wherein the plurality of cutouts are formed by punching holes with a tab in a metal sheet and thinning the tab.
10. The method of claim 9 , wherein each of the plurality of tabs are less than 1.0 mm thick.
11. The method of claim 9 , wherein the busbar comprises a metal sheet.
12. The method of claim 9 , wherein the plurality of cutouts are arranged into one or more rows.
13. The method of claim 9 , wherein the plurality of cutouts are further formed by bending the thinned tab into a springable profile.
14. The method of claim 9 , wherein the busbar is positioned on a bottom plane of the battery pack.
15. The method of claim 9 , wherein the busbar is more than 1.0 mm thick.
16. The method of claim 9 , further comprising positioning a second busbar on a top plane of the battery pack in contact with the second terminal of the subset of battery cells.