Busbar module for traction battery pack
AssigneeFord Global Technologies, LLC
InventorsAntony George Schepak, Daniel Benjamin Kok, Patrick Daniel Maguire, Mohammadreza Eftekhari, Deanna Marie Winton Hoffman
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Abstract
A traction battery pack may include a housing. The traction battery pack may also include a plurality of battery cells arranged within the housing. Further, the traction battery pack may include a busbar configured to electrically connect the battery cells. The busbar may be partially embedded in a polymer material so as to provide an embedded busbar. The embedded busbar establishes at least a portion of the housing.
Claims20
A traction battery pack, comprising:
- a housing;
- a plurality of battery cells arranged within the housing;
- and
- a busbar configured to electrically connect the battery cells, wherein the busbar is partially embedded in a polymer material so as to provide an embedded busbar, and wherein the embedded busbar establishes at least a portion of the housing.
The traction battery pack as recited in claim 1, further comprising:
- a first layer of polymer material adjacent the battery cells;
- and
- a second layer of polymer material, wherein the busbar is arranged between the first and second layers of polymer material.
The traction battery pack as recited in claim 2, further comprising:
- a sensing circuit, wherein the sensing circuit is also arranged between the first and second layers of polymer material.
The traction battery pack as recited in claim 3, wherein the sensing circuit is configured to sense a voltage of the battery cells.
The traction battery pack as recited in claim 6, wherein the second layer of polymer material includes a plurality of openings aligned with the nodes to facilitate welding of the nodes to a corresponding one of the battery cells.
The traction battery pack as recited in claim 13, wherein the battery cells are arranged in staggered rows.
An electrified vehicle, comprising:
- a traction battery pack, wherein the traction battery pack comprises a housing, a plurality of battery cells arranged within the housing, and a busbar configured to electrically connect the battery cells, wherein the busbar is partially embedded in a polymer material so as to provide an embedded busbar, and wherein the embedded busbar establishes at least a portion of the housing.
The electrified vehicle as recited in claim 15, further comprising:
- a first layer of polymer material adjacent the battery cells;
- and
- a second layer of polymer material, wherein the busbar is arranged between the first and second layers of polymer material.
The electrified vehicle as recited in claim 16, wherein:
- the first layer of polymer material includes a plurality of openings,
- the busbar includes a plurality of nodes,
- each of the nodes is configured to project through one of the openings to electrically couple to one of the battery cells.
A method, comprising:
- at least partially embedding a busbar of a traction battery pack of an electrified vehicle within a polymer material.
The method as recited in claim 19, wherein the busbar is overmolded with the polymer material.
Dependencies are inferred from the claim text.