Battery Interconnect Blade Coupling to Non-Conductive Base
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Solution Overview
Problem
Existing battery systems require numerous labor-intensive brackets and bolts for coupling battery modules to an electrical bus, making the process inefficient.
Innovation Solution
A battery system with interconnect members having blades that removably fit into apertures of bus bar members disposed within an electrically non-conductive base member, simplifying the coupling process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If numerous brackets and bolts are used to couple battery modules to an electrical bus, then the connection strength and reliability are improved, but the labor intensity and assembly complexity increase significantly
Solution Approach 1:
The patent combines multiple separate components (brackets and bolts) into a single integrated interconnect member with an integrated blade structure. The interconnect member simultaneously provides mechanical support and electrical connection functions, eliminating the need for separate brackets and multiple bolts, thus reducing assembly complexity while maintaining connection reliability
Solution Approach 2:
The interconnect member is designed as a multi-functional component that serves both mechanical support and electrical conduction purposes. The blade portion provides both structural attachment and electrical connection to the bus bar, consolidating multiple functions into a single component that reduces the overall number of parts needed
2Strength
If numerous brackets and bolts are used to couple battery modules to an electrical bus, then the mechanical strength of the connection is improved, but the assembly time and labor intensity increase
Solution Approach 1:
The interconnect member is segmented into distinct functional portions: a support portion for mechanical attachment and a blade portion for electrical connection. This segmentation allows each portion to be optimized for its specific function while being manufactured as a single integrated component, reducing assembly time through simplified installation
Solution Approach 2:
The patent merges the support portion and blade portion into a single interconnect member that can be installed as one unit. This consolidation eliminates the need for separate assembly steps for brackets and bolts, significantly reducing labor intensity and assembly time while maintaining the mechanical strength required for secure connection
3Reliability
If traditional brackets and bolts are used for coupling, then the electrical connection is established, but the number of components and material usage increase
Solution Approach 1:
The patent extracts and eliminates unnecessary components from the traditional assembly system. By removing separate brackets and reducing multiple bolts to a single integrated interconnect member with blade structure, the design minimizes the quantity of components and materials required while maintaining reliable electrical connection through the conductive blade-to-aperture interface
Data Source
AI summary
A battery system is provided. The battery system includes a first battery cell assembly having first and second interconnect members. The first and second interconnect members have first and second blades, respectively. The battery system further includes an electrically non-conductive base member having first and second grooves. The battery system further includes first and second bus bar members disposed in the first and second grooves, respectively. The first bus bar member has a first aperture configured to removably receive the first blade therein. The second bus bar member has a second aperture configured to removably receive a second blade therein.