Overlapping Bus Plate Battery Pack for Short-Circuit Isolation
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Solution Overview
Problem
Existing battery packs with multiple secondary batteries face challenges in maintaining stable mechanical and electrical connections over time, leading to potential electrical short circuits and inefficient space utilization.
Innovation Solution
A battery pack design featuring first and second conductive plates that partially overlap each other, with an insulating layer in between, and a cooling member below the battery cells, ensuring electrical connectivity without direct contact and improving space efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If battery packs are made larger to increase energy storage capacity, then the running time of portable devices is extended, but the size and weight of the device increase
Solution Approach 1:
The battery pack is divided into multiple individual battery cells (e.g., five battery cells) arranged in series. This segmentation allows the total voltage to be achieved through configuration rather than using a single large cell, enabling modular design that can be optimized for both capacity and weight.
Solution Approach 2:
The battery cells are nested within a compact housing structure with integrated support elements. The support elements are positioned between the battery cells, creating a nested arrangement that maximizes space utilization and reduces overall pack volume and weight while maintaining structural integrity.
2Duration of action of moving object
If battery packs are made larger to increase energy storage capacity, then the running time of portable devices is extended, but the volume of the device increases
Solution Approach 1:
The battery cells are arranged in a multi-dimensional configuration rather than a simple linear arrangement. By utilizing three-dimensional space efficiently with vertical stacking and strategic positioning of support elements, the design achieves high energy density without increasing external volume.
Solution Approach 2:
The support elements are integrated between the battery cells in a nested configuration, eliminating the need for separate structural components. This nesting approach reduces overall volume by utilizing the interstitial spaces between cells for structural support functions.
3Reliability
If connection elements are used to connect battery cells, then electrical connection is achieved, but contact resistance increases and heat generation occurs
Solution Approach 1:
The support element and connection element are merged into a single integrated component. This eliminates the need for separate connection elements and reduces the number of interfaces between components, thereby minimizing contact resistance and heat generation at connection points.
Solution Approach 2:
The support element is made from a composite material or material with high electrical conductivity (such as aluminum alloy or copper alloy) that provides both mechanical support and electrical connection functions with low contact resistance, reducing energy loss and heat generation.
4Stability of the object's composition
If support elements are added to hold battery cells, then structural stability is improved, but device complexity increases
Solution Approach 1:
The support element and connection element are combined into a single integrated component that performs both mechanical support and electrical connection functions. This merging reduces the total number of parts and simplifies the overall structure while maintaining structural stability.
Solution Approach 2:
The support element is designed to perform multiple functions simultaneously: providing mechanical support for battery cells, establishing electrical connections between cells, and facilitating heat dissipation. This multi-functionality reduces structural complexity by eliminating the need for separate components for each function.
Data Source
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Figure 2B
AI summary
Provided is a battery pack including: a plurality of battery cells; a first conductive plate arranged over the plurality of battery cells and electrically connecting the plurality of battery cells; a second conductive plate arranged over the first conductive plate to overlap a portion of the first conductive plate and electrically connecting the plurality of battery cells; and an insulating layer arranged between the first conductive plate and the second conductive plate.