Injection-Molded Bus Bar Battery Pack for Compact Cell Connection
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Solution Overview
Problem
Existing portable power devices, such as battery packs, face challenges in efficiently connecting and supporting multiple battery cells while maintaining a compact and efficient design for mobile power sources.
Innovation Solution
The design incorporates multiple battery cell assemblies with cylindrical recesses and bus bars that are injection molded into the support members, allowing for secure support and electrical connection of battery cells, with bus bars featuring elongated conductive bodies and fingers for efficient electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple battery cells are connected using traditional connection methods, then electrical connectivity is achieved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The bus bar integrates both mechanical support and electrical connection functions into a single component. The support member holds multiple battery cells while the bus bar simultaneously provides electrical connectivity, eliminating the need for separate connection hardware and reducing overall assembly complexity
Solution Approach 2:
The bus bar structure serves multiple functions: it provides structural support for battery cells, establishes electrical connections between cells, and enables modular assembly. This multi-functional design reduces the number of components needed and simplifies the overall battery pack construction
2Stability of the object's composition
If battery cells are securely supported using traditional support structures, then structural stability is achieved, but manufacturing precision requirements increase
Solution Approach 1:
The support members extend in multiple dimensions to provide comprehensive battery cell support. By utilizing three-dimensional spatial arrangement with support members positioned at different heights and orientations, the structure achieves enhanced stability without requiring extremely tight manufacturing tolerances in any single dimension
3Reliability
If bus bars are designed with multiple fingers for efficient electrical connection, then electrical conductivity is improved, but device complexity increases
Solution Approach 1:
The bus bar is segmented into multiple fingers that can be independently positioned to contact different battery cell terminals. This segmentation allows for efficient electrical connectivity across multiple cells while maintaining a modular structure that is easier to manufacture and assemble compared to a single complex piece
Data Source
AI summary
A mobile power source that has a battery pack including at least two battery cell assemblies each having frame that has a first support member and a second support member, each of the first and second support members including a plurality of cylindrical recesses that receive the plurality of battery cells to support the battery cells. Bus bars are coupled to the first support member via injection molding and each is configured to electrically connect to at least two battery cells. The bus bars each include an elongated conductive body that has a base and fingers extending laterally away from the base. Each of the fingers extend within a first plane, and the base extends within a second plane that is parallel to the first plane and offset therefrom.