Battery Beam Structure for Isolated Wire Routing and Heat Dissipation
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Solution Overview
Problem
Conventional battery structures face issues with electric leakage due to insulation breakage of external connecting wires rubbing against the housing and electrolyte spills causing connection failures between the wires and cells.
Innovation Solution
A battery design incorporating a beam structure within the housing to isolate and securely route external connecting wires using clamps and heat-conducting components, preventing direct contact and facilitating stable assembly and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If external connecting wires are placed in gaps between cells and housing to reduce battery size, then battery compactness is improved, but insulation reliability deteriorates due to wire rubbing against housing causing electric leakage
Solution Approach 1:
The patent introduces a beam structure as an intermediary component between the cells and the housing. This beam structure provides a dedicated routing path for external connecting wires, isolating them from direct contact with the housing. The beam structure acts as a mediator that separates the wires from the housing surface, preventing rubbing and insulation damage while maintaining compact battery design.
2Volume of moving object
If external connecting wires are placed close to cells to reduce battery size, then battery compactness is improved, but connection reliability deteriorates due to electrolyte spurring causing electrical connection failure
Solution Approach 1:
The beam structure serves as a protective intermediary that positions external connecting wires away from direct exposure to electrolyte spurring from cells. By routing wires through or along the beam structure rather than placing them directly adjacent to cells, the design reduces the risk of electrolyte contamination while maintaining compact overall battery dimensions.
3Reliability
If external connecting wires are isolated from cells using beam structure, then insulation reliability is improved, but device complexity increases due to additional beam structure components
Solution Approach 1:
The beam structure is designed to serve multiple functions simultaneously: it provides structural support for the battery assembly, creates dedicated routing channels for external connecting wires, and acts as an insulating barrier between wires and housing. This multi-functionality reduces the need for separate isolation components, thereby limiting the increase in overall structural complexity while achieving improved insulation reliability.
4Stability of the object's composition
If clamp is used to fix external connecting wire in accommodating space, then assembly stability is improved, but manufacturing complexity increases due to additional clamping mechanism
Solution Approach 1:
The clamp is integrated as part of the beam structure assembly rather than being a completely separate component. The beam structure includes built-in features such as recesses or mounting points that accommodate the clamp, combining the support function and the clamping function into a unified structural element. This integration simplifies the manufacturing process compared to using entirely separate clamp components.
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
Prevents electric leakage and connection failures by isolating external connecting wires from the cells and ensuring stable routing, while enhancing heat dissipation to prevent overheating.
Implementation Method 1
a heat-conducting component, which is arranged in the accommodating space, and at least a part of which is attached to the external connecting wire and at least another part of which is attached to an inner wall of the beam structure
Data Source
AI summary
A battery includes a housing, and a beam structure and a group of cells which are arranged in the housing. The beam structure is fixed to the housing, and an accommodating space is formed in the beam structure. An external connecting wire of the group of cells is arranged in the accommodating space.