Comb-Shaped Battery Terminal Straps for Low-Profile Battery Banks
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Solution Overview
Problem
Existing battery energy storage systems face challenges in achieving a low profile design for residential applications, which restricts the selection of battery cabinets and limits their unobtrusive wall mounting, especially in spaces like garages where space is limited.
Innovation Solution
A rectangular box-shaped battery cabinet with parallel shelves supporting battery modules or adapters that snugly fit selected battery cells, allowing for a low profile depth of less than 8 inches, with integrated fasteners and adapters for secure and resilient connection of battery cells, enabling efficient packing and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If battery cells are arranged in a conventional cabinet configuration, then energy capacity is achieved, but cabinet depth exceeds 8 inches making it unsuitable for low profile residential wall mounting
Solution Approach 1:
The patent reconfigures the battery arrangement from a conventional depth-oriented layout to a width-oriented layout. Multiple battery cells are arranged side-by-side in parallel columns within the cabinet, utilizing the width dimension rather than the depth dimension to achieve the required energy capacity. This dimensional shift allows the cabinet depth to be reduced to less than 8 inches while maintaining adequate energy storage capacity through increased width and optimized cell density.
2Reliability
If battery cells are securely connected with individual fasteners, then connection reliability is improved, but device complexity and assembly time increase
Solution Approach 1:
The patent combines multiple individual fasteners into a single integrated strap component that spans across multiple battery terminals. This unitary strap simultaneously secures several battery cells to the cabinet structure, replacing what would otherwise require multiple separate fasteners. The merged design maintains secure connections and high reliability while significantly reducing the total number of fastening operations and simplifying the overall device complexity.
Solution Approach 2:
The strap component serves multiple functions simultaneously: it acts as a mechanical fastener securing battery cells, provides electrical insulation between terminals, and serves as a structural support element. This multi-functional design eliminates the need for separate components for each function, reducing the number of parts and simplifying assembly while maintaining connection reliability.
3Productivity
If battery cells are tightly packed to maximize energy capacity, then productivity is improved, but thermal management and airflow become restricted
Solution Approach 1:
The patent implements differentiated spacing strategies in different regions of the cabinet. Battery cells in the interior are tightly packed to maximize energy density, while cells along the cabinet walls and between vertical columns maintain increased spacing. This local variation in density allows tight packing where space is critical while preserving thermal management pathways and airflow channels in strategic locations, balancing productivity and temperature control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a compact battery bank with a desired energy capacity, allowing for unobtrusive residential wall mounting and efficient energy storage and retrieval, while maintaining the integrity and longevity of the battery cells through secure connections and thermal management.
Implementation Method 1
Terminals of each polarity are connected to a comb-shaped battery strap where the comb has blades, each blade welded to a battery terminal
Implementation Method 2
each blade welded to a battery terminal
Data Source
AI summary
A battery cabinet with a plurality of spaced apart shelves of equal width and depth. Each shelf supports a removable battery module. In turn, each module has a fixed adapter that holds batteries as a battery bank where the module and adapter occupy most of the space between shelves. Battery cells are vertically or horizontally aligned with terminals joined to comb-shaped straps with blades joined to battery terminals. The space between blades allows for thermal expansion without wear on terminals.