Battery Module Insulator Structure for Simpler Busbar Insulation
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Solution Overview
Problem
Existing energy storage devices face high costs and complex processes due to the use of wires and heat-shrinkable sleeves for insulation, which complicate the series-parallel connection of battery modules.
Innovation Solution
An energy storage device design featuring a housing with connectors, battery modules, buses, connecting rods, and insulators with bridging and protrusion portions for insulation, eliminating the need for additional insulation components and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wires with outer covers or heat-shrinkable sleeves are used for insulation, then insulation protection is achieved, but cost increases and process complexity increases
Solution Approach 1:
The insulator integrates multiple functions into a single component: it provides electrical insulation, structural support for positioning batteries and buses, and mechanical connection features. This merging eliminates the need for separate wire insulation components and simplifies the overall assembly process while maintaining reliable insulation protection.
Solution Approach 2:
The insulator serves multiple purposes simultaneously: it acts as an insulating barrier, a mounting structure for batteries and buses, a positioning element with protrusion portions, and a protective cover. This multi-functionality reduces the total number of components needed and simplifies both manufacturing and assembly processes.
2Reliability
If wires with outer covers or heat-shrinkable sleeves are used for insulation, then insulation protection is achieved, but cost increases
Solution Approach 1:
The insulator combines insulation functionality with structural support and positioning features into one integrated component. This eliminates the need for separate wire insulation purchases and installations, reducing overall material costs and simplifying the bill of materials while ensuring reliable insulation protection.
Solution Approach 2:
The insulator's integrated design allows it to perform multiple functions without requiring additional components or complex assembly steps. The protrusion portions automatically position batteries and buses, while the body provides both insulation and structural support, making the manufacturing process more cost-effective.
3Reliability
If heat-shrinkable sleeves are used for insulation, then insulation protection is achieved, but additional heat-shrinking procedures are required
Solution Approach 1:
The insulator integrates insulation protection with structural support and positioning functions in a single component that requires no additional processing steps. This eliminates the separate heat-shrinking procedure entirely, as the insulator is designed to fit directly onto connecting rods without requiring thermal contraction.
4Reliability
If traditional wire insulation methods are used, then insulation is provided, but the design becomes complex
Solution Approach 1:
The insulator merges insulation functionality with structural support, positioning features, and connection elements into a single integrated component. This consolidation simplifies the overall device design by reducing the number of separate parts and their associated assembly instructions, while maintaining effective insulation protection.
Data Source
AI summary
The invention discloses an energy storage device, comprising: a housing provided with at least one connector; and a battery module arranged in the housing, the battery module including: a plurality of batteries; a battery rack accommodating the plurality of batteries; at least one bus arranged on a surface of the battery rack and connected to the plurality of batteries; at least one connecting rod connected between the bus and the connector; and at least one insulator sheathed onto the connecting rod. The insulator is provided with a bridging portion, two side pieces, and two inward protrusion portions. An opening end is formed between ends of the two side pieces. The connecting rod passes through the opening end and is sheathed by the insulator. Therefore, the battery module of the present invention has low cost and simple design.