Battery Block Bus Bar Insulation Holder Design
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Solution Overview
Problem
Existing battery block configurations, such as those disclosed in PTL 1, require increased manufacturing and material costs due to the need for holes in bus bars and insulation plates for wire passage and a larger area coverage when batteries are arranged in arrays, making them less adaptable and costly for various battery arrangements.
Innovation Solution
A battery block design where assembled batteries are connected in parallel with insulated terminals, using bus bars held by insulation holders, allowing for flexible arrangement without the need for additional holes or increased material, and enabling efficient parallel connection with minimal components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If positive-electrode bus bars and negative-electrode bus bars are stacked on each other with an insulation plate interposed therebetween, then electrical insulation is ensured, but holes must be formed in the bus bars and insulation plate for wire passage, increasing manufacturing cost
Solution Approach 1:
The patent introduces an insulation holder as an intermediary component that supports the bus bars and provides electrical insulation. The insulation holder includes insulating ribs that extend between the positive and negative bus bars, eliminating the need for holes in traditional insulation plates while maintaining electrical isolation. This mediator approach resolves the contradiction by providing insulation through a dedicated structural element rather than modifying the bus bars themselves.
Solution Approach 2:
The insulation holder is segmented into multiple insulating ribs that are distributed between the bus bars. Each rib provides localized insulation support, allowing the system to maintain electrical isolation without requiring continuous insulation plates with holes. This segmentation enables simpler manufacturing while ensuring reliable insulation at critical points.
2Reliability
If bus bars are formed as flat plates covering all batteries in an array arrangement, then complete coverage is achieved, but the area is increased, thus increasing material cost
Solution Approach 1:
Instead of using uniform flat plate bus bars that cover the entire battery array, the patent employs bus bars with localized connection points supported by insulating ribs. The bus bars are configured to make contact only at necessary locations with individual batteries, providing complete electrical coverage without requiring excessive material area. This local quality approach ensures reliable connections while minimizing material usage.
3Adaptability or versatility
If holes are formed in bus bars and insulation plate for wire passage, then battery arrangement flexibility is reduced, but manufacturing complexity is increased for various arrangements
Solution Approach 1:
The insulation holder with its modular insulating ribs provides a dynamic and adaptable structure that can accommodate different battery arrangements. The ribs can be positioned and configured to support bus bars in various layouts without requiring predetermined holes. This dynamic structure allows the same basic component design to serve multiple battery configurations, maintaining flexibility while reducing manufacturing complexity.
Data Source
AI summary
A battery block includes assembled batteries that are arranged in parallel to each other, and the plurality of assembled batteries are each formed of a plurality of batteries as a unit. Each of the batteries has a positive-electrode terminal and a negative-electrode terminal on one end portion of the battery. The assembled battery includes: the plurality of batteries which are arranged in a row with one end portions of the batteries directed in the same direction; an insulation holder which is arranged on one end portion side of the batteries and holds the batteries; and a positive-electrode bus bar and a negative-electrode bus bar arranged on one end portions of the batteries. The positive-electrode bus bar and the negative-electrode bus bar are respectively held by holding portions which are formed on the insulation holder along a row direction and in parallel to each other.