Dual Rack Battery Assembly with Bus Bar Short Circuit Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery assemblies face challenges in preventing electric shorts when multiple battery modules are connected, and they often require complex and costly configurations to accommodate a large number of modules efficiently.
Innovation Solution
A dual rack housing system with opposite front and rear opening portions accommodates battery modules, featuring bus bars that connect terminals of opposite polarities and a rotation bound device to prevent arbitrary rotation and short circuits, allowing for efficient stacking and connection of battery modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple battery modules are connected in existing battery assemblies, then the battery capacity increases, but electric shorts may occur between connected modules
Solution Approach 1:
The patent introduces a bus bar as an intermediary component to connect battery modules. The bus bar includes a connection portion that contacts terminals and an extension portion that extends outward, serving as a mediator to establish electrical connections while preventing direct contact between opposing terminals of different modules, thus avoiding electric shorts.
Solution Approach 2:
The patent segments the battery assembly into multiple independent modules, each with its own terminals. By separating the positive and negative terminals into distinct modules and using bus bars for connection, the design prevents direct shorting between opposite polarity terminals while maintaining scalability for increased capacity.
2Quantity of substance
If complex configurations are used to accommodate large numbers of battery modules, then the battery capacity increases, but the manufacturing cost increases
Solution Approach 1:
The bus bar design serves multiple functions: it provides electrical connection between modules, acts as a structural support element, and prevents electric shorts through its geometric configuration. The rotation bound device also serves dual purposes by both securing the bus bar and preventing short circuits. This multi-functionality reduces the need for additional specialized components, thereby lowering manufacturing costs.
Solution Approach 2:
The patent combines the electrical connection function and the short prevention function into a single integrated bus bar structure. Additionally, the rotation bound device merges structural securing with electrical isolation functionality. This consolidation reduces component count and assembly complexity, leading to lower manufacturing costs.
3Volume of moving object
If battery modules are accommodated in a compact space, then the space utilization improves, but the risk of electric shorts increases
Solution Approach 1:
The bus bar extends in a direction outward from the battery module rather than directly connecting adjacent modules face-to-face. This dimensional arrangement creates spatial separation between opposite polarity terminals while maintaining electrical connection through the extended bus bar, effectively preventing shorts in compact configurations.
Solution Approach 2:
The bus bar acts as a mediator that maintains safe distances between battery modules while enabling electrical connection. The extension portion of the bus bar reaches outward to connect with adjacent modules without requiring direct contact between module terminals, thus preventing shorts even in tightly packed arrangements.
Data Source
AI summary
A battery assembly includes a rack housing including a front opening portion and a rear opening portion open in opposite directions; and a plurality of battery modules accommodated in the rack housing. The battery assembly includes a dual rack housing capable of accommodating a plurality of battery modules through opposite sides, such as a front surface and a rear surface, and thus, may prevent short circuits when the battery modules accommodated in the rack housing are electrically connected.