Enclosed Bus Bar System for Safe Battery Replacement
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Solution Overview
Problem
Existing battery systems with exposed bus bars require sophisticated equipment and trained technicians for maintenance, leading to high costs and extended downtime due to the risk of accidental contact and the need for laboratory access.
Innovation Solution
A battery system design featuring a bus bar system enclosed within panels, with coupling elements that prevent accidental contact, allowing for quick and easy replacement of batteries without specialized equipment or technical expertise, using a modular structure with a backbone system to connect battery modules safely.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If exposed bus bar design is used, then electrical connection is achieved, but maintenance safety deteriorates due to risk of accidental contact
Solution Approach 1:
The bus bar is nested within a cavity formed by the first and second panels, with the second panel's lower surface extending over the cavity to enclose the bus bar. This nesting structure provides physical protection while maintaining electrical connection functionality, directly addressing the safety hazard of exposed bus bars.
Solution Approach 2:
The cavity structure acts as an intermediary barrier between the bus bar and external environment, preventing direct contact while allowing electrical connections to be made through designated access points. This mediator structure resolves the contradiction by providing both protection and functionality.
2Ease of repair
If exposed bus bar design is used, then electrical connection is achieved, but repair complexity increases due to need for specialized equipment and trained technicians
Solution Approach 1:
The battery system is segmented into modular units with individual battery modules that can be replaced independently. The backbone structure with standardized cavities and coupling elements enables modular replacement without requiring disassembly of the entire system or specialized laboratory equipment.
Solution Approach 2:
The design enables end-users to perform battery replacements themselves through simple coupling element mechanisms that require no specialized tools or technical expertise. The self-service capability is achieved through intuitive mechanical coupling and positioning features.
3Productivity
If traditional battery system design is used, then electrical functionality is maintained, but downtime increases during repairs
Solution Approach 1:
The backbone structure with pre-formed cavities and positioning features is prepared in advance to receive battery modules. Coupling elements are pre-configured to enable quick connection and disconnection, allowing rapid battery replacement without system disassembly or reconfiguration.
Solution Approach 2:
The system employs dynamic coupling elements that can be quickly connected and disconnected to facilitate rapid battery module replacement. The mechanical coupling design allows for fast attachment and detachment operations, minimizing system downtime during maintenance.
Data Source
AI summary
An apparatus may include a first panel including a first upper surface and a first lower surface. The first upper surface may include a cavity extending into the first upper surface towards the first lower surface and a bus bar within the cavity. In addition, the apparatus may include a second panel having a second lower surface in direct contact with the first upper surface, wherein the second lower surface extends over a substantial portion of the cavity. In addition, the bus bar may include a first coupling element. The first coupling element may be configured to be mechanically coupled to a terminal of a battery module. Further, the cavity may position the first coupling element to align with the terminal.