Battery Pack Output Layout Without Long Cross-Pack Busbars
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Solution Overview
Problem
Existing battery manufacturing processes result in increased weight and cost due to the arrangement of a long output member across the entire battery, which complicates processing, assembly, and reduces integration and energy density.
Innovation Solution
A battery design featuring multiple battery groups arranged along a direction with busbars connecting adjacent cells, allowing output members to be placed on the same side, eliminating the need for a long output member across the battery and improving space utilization, assembly efficiency, and energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a long output member is arranged across the entire battery to connect battery groups, then the electrical connection is achieved, but the weight and cost increase
Solution Approach 1:
The patent divides the battery into multiple battery groups arranged in parallel, with each group having its own output terminals. Instead of using one long output member to connect all battery groups in series, the invention segments the electrical connection into multiple shorter connections through busbars within each group, reducing the total length and weight of output members required.
Solution Approach 2:
The patent transitions from a linear arrangement of battery groups connected by a single long output member to a parallel arrangement where multiple battery groups are connected through busbars in a two-dimensional configuration. This dimensional change allows output members to be positioned on the same side, reducing the need for longè·¨-battery connections.
2Reliability
If a long output member is arranged across the entire battery, then the power supply path is formed, but the space utilization decreases
Solution Approach 1:
The power supply path is segmented into multiple shorter paths within each battery group, connected through busbars. This segmentation allows the output members to be positioned locally within each group rather than spanning the entire battery length, improving space utilization.
Solution Approach 2:
Multiple battery groups are merged in parallel configuration, sharing common output terminals on the same side. This merging allows the power supply paths to converge at localized points rather than requiring a single long path across the entire battery, improving space efficiency.
3Reliability
If a long output member is used to connect battery groups, then the electrical connection is established, but the assembly complexity increases
Solution Approach 1:
The battery assembly is segmented into independent battery groups that can be assembled and tested separately before final integration. Each group has its own busbar connections, allowing modular assembly and reducing the complexity of handling long output members across the entire battery.
Solution Approach 2:
Busbars are pre-assembled within each battery group to establish local electrical connections before the groups are integrated into the final battery assembly. This preliminary action simplifies the overall assembly process by reducing the number of long-distance connections that need to be made during final assembly.
Data Source
AI summary
A battery includes a box, battery groups arranged along a first direction, a busbar, and two output members. Each battery group includes an even number of battery cells arranged along a second direction perpendicular to the first direction, and each including first and second side walls connected to each other. The first side wall having the largest area among all the outer walls of the battery cell. The second side walls of two adjacent battery cells are arranged opposite to each other along the second direction. The busbar is used to electrically connect two adjacent battery cells. The two output members are arranged on the same side of the first direction. The outermost battery group along the first direction is provided with two output terminals distributed along the second direction and electrically connected respectively to the two output terminals to form a power supply path together with the busbar.