Battery Block Partial-Stack Fastening for Compact Footprint
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Solution Overview
Problem
Existing battery systems with internal connecting bolts face challenges in tightly connecting battery units without increasing the footprint, especially when multiple levels are stacked, as long thin bolts can loosen and wide bolts protrude, interfering with bus-bars.
Innovation Solution
The battery system employs connecting cylinders at the perimeters of battery holders, with rows of partial-stack cylinders on multiple levels, allowing shorter connecting bolts to securely hold fewer levels, reducing the footprint and preventing loosening, and using main bolts for additional stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the diameter of connecting bolts is increased to prevent stretching, then the connecting bolts can reliably hold battery units stacked in many levels, but the connecting cylinders must be made wider, increasing the battery unit outline
Solution Approach 1:
The patent segments the connecting bolt system into multiple shorter bolts with standard diameters, eliminating the need for oversized bolts. This allows connecting cylinders to maintain compact dimensions while still providing reliable holding for many levels of battery units through the distributed bolt configuration.
2Reliability
If many wide connecting cylinders are provided to accommodate large diameter connecting bolts, then the connecting bolts can reliably hold battery units, but the connecting cylinders protrude from battery unit perimeters, increasing the footprint
Solution Approach 1:
The patent segments the connecting bolt system into multiple shorter bolts with standard diameters, which allows connecting cylinders to be compact and not protrude significantly from battery unit perimeters. This segmentation maintains reliable holding while minimizing the footprint.
3Ease of manufacture
If connecting bolts pass through the interior of battery units, then the battery units can be connected, but space for bolt insertion must be allocated between adjacent batteries, increasing the battery unit outline
Solution Approach 1:
The patent extracts the connecting bolts from the interior of battery units and relocates them to the perimeters. This extraction eliminates the need for internal space allocation for bolt insertion, thereby reducing the battery unit outline while maintaining the ease of connecting battery units through perimeter-based assembly.
4Reliability
If connecting bolts are strongly tightened to solidly attach battery units, then the battery units can be reliably connected, but the battery unit center regions can indent, making tight connection at the peripheries even more difficult
Solution Approach 1:
The patent extracts the connecting bolts from interior locations and relocates them to perimeter locations. This extraction prevents the indenting of battery unit center regions that occurs with strong interior bolt tightening, thereby maintaining ease of manufacture for tight peripheral connections while achieving reliable battery unit attachment.
Data Source
AI summary
The connecting bolts 5 are inserted through the connecting cylinders 21 to hold a plurality of battery holders 20 in the stacked configuration and form a battery block 2. The battery holder 20 connecting cylinders 21 are disposed at a plurality of locations on the perimeter of the battery block 2, and are disposed in straight-lines to form rows of partial-stack connecting cylinders 4 on battery holders 20 stacked in two levels or more, but not on the entire stack of battery holders 20. Connecting bolts 5 are inserted through each row of partial-stack connecting cylinders 4 to hold the connecting cylinders 21 that make up each row of partial-stack connecting cylinders 4 in a stacked configuration, and retain the battery holders 20 in a stacked configuration as a battery block 2.