Modular Battery Pack With Shifted Cell Rows And Asymmetric Busbars
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery packs for high-power devices like electric vehicles lack flexibility and expandability to meet varying power and capacity requirements, as they are typically designed with fixed configurations that do not easily adapt to different operational needs.
Innovation Solution
The battery pack design features a modular structure with alternately shifted rows of battery cells and busbars, allowing for easy expansion by connecting multiple packs with complementary shapes and connection mechanisms, enabling flexible power and capacity adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If battery packs are designed with fixed configurations, then manufacturing and assembly are simplified, but flexibility and expandability to meet varying power and capacity requirements are reduced
Solution Approach 1:
The battery pack is divided into modular components including battery cell modules, busbar assemblies, and case sections. Each module can be independently configured and assembled, allowing the overall system to be scaled and adapted to different power and capacity requirements while maintaining standardized manufacturing processes for each segment
Solution Approach 2:
The busbar is designed with universal connection features including protruding connection portions at both ends that can connect to different battery cell configurations. The same busbar structure can serve multiple functions by adjusting the number and arrangement of battery cells, enabling a single design to meet varying power and capacity needs without requiring completely different structures
2Adaptability or versatility
If battery cells are arranged in fixed rows, then manufacturing precision is improved, but adaptability to different power and capacity requirements is reduced
Solution Approach 1:
The battery cell rows are designed with adjustable positioning features that allow the number of rows and cells per row to be dynamically changed. The case includes guide structures and mounting positions that maintain precise alignment while accommodating different configurations, enabling the same manufacturing process to produce various power and capacity arrangements
3Adaptability or versatility
If busbar connection portions have different lengths and levels, then expandability and flexibility are improved, but manufacturing complexity increases
Solution Approach 1:
The busbar connection portions are deliberately designed with asymmetric features including different lengths and levels at different ends. This asymmetric design allows the same busbar component to accommodate various battery cell arrangements and expansion configurations. The asymmetry is built into the standard manufacturing process, allowing easy production of adaptable components that can connect to different configurations without requiring custom manufacturing for each application
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A battery pack includes: a plurality of battery cells arranged in a plurality of rows extending in a row direction, the battery cells being arranged such that rows adjacent to each other in a transverse direction crossing the row direction are alternately shifted to forward and backward positions in the row direction; a busbar extending in the row direction, the busbar including: a busbar body portion extending in the row direction; a busbar front connection portion at one end of the busbar; and a busbar rear connection portion at another end of the busbar, the busbar front connection portion and the busbar rear connection portion protruding from the busbar body portion and having different lengths and levels from each other; and a case accommodating the battery cells, the case including a front wall and a rear wall having complementary shapes and facing each other in the row direction with the battery cells therebetween.