Battery Module Assembly for Cooling and Shock Stability
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Solution Overview
Problem
Conventional energy storage systems face challenges in maintaining stable disposition and connection of battery cells, accommodating size variations, and effective cooling, particularly due to restrictive bus bar designs and inadequate shock absorption, which can lead to damage during installation, movement, or external shocks.
Innovation Solution
The energy storage system incorporates a configuration with facing battery modules connected by module screws, upper and lower fixing brackets, and insulating plates, along with side covers and brackets for enhanced stability, cooling, and shock absorption, allowing for flexible module arrangement and efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional bus bars with same shape are used, then manufacturing is simplified, but adaptability for size changes is restricted
Solution Approach 1:
The bus bar is divided into multiple segments (first bus bar and second bus bar) that can be independently positioned and connected. This segmentation allows the bus bar structure to adapt to different battery pack sizes while maintaining standardized manufacturing processes for each segment.
Solution Approach 2:
The bus bar structure is made adjustable through positioning holes and fastening mechanisms, allowing dynamic reconfiguration of the bus bar arrangement to match different battery cell configurations and pack sizes, rather than being fixed in a single rigid design.
2Temperature
If cooling water circulation structure is added, then cooling effectiveness is improved, but device complexity increases
Solution Approach 1:
The cooling function is merged with the existing battery pack structure by utilizing the casing and internal space for cooling water circulation, rather than adding completely separate cooling components. The cooling water channel is integrated into the casing structure, combining structural support and thermal management functions.
Solution Approach 2:
The cooling water circulation system is designed to work with the existing battery pack structure, where the casing serves multiple functions: structural enclosure, shock absorption, and cooling water channel. This multi-functionality reduces overall system complexity while maintaining effective cooling.
3Ease of manufacture
If rectangular parallelepiped casing structure is used, then manufacturing is simplified, but shock absorption capability is reduced
Solution Approach 1:
The casing incorporates shock-absorbing structures and cushioning elements positioned in advance to mitigate external shocks before they reach the battery cells. These cushioning features are integrated into the casing design to protect against drops and external impacts while maintaining the overall rectangular form factor.
4Device complexity
If only lower side fixing structure is provided, then device complexity is reduced, but disposition stability is insufficient
Solution Approach 1:
Fixing structures are added at specific critical locations (upper side and side surfaces) where stability is most needed, rather than uniformly throughout the entire structure. This targeted approach provides necessary stabilization while minimizing additional complexity.
Data Source
AI summary
An energy storage system of the present disclosure includes: a first battery module in which a plurality of battery cells are disposed; a second battery module in which a plurality of battery cells are disposed, and which is disposed to face the first battery module; a module screw which extends in a front-rear direction in which the first battery module and the second battery module are disposed, and fastens the first battery module and the second battery module; an upper fixing bracket which is disposed in an upper side of the first battery module and the second battery module, and fixes the first battery module and the second battery module; and a lower fixing bracket which is disposed in a lower side of the first battery module and the second battery module, and fixes the first battery module and the second battery module.