Energy Storage Device Terminal Substrate Integration
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Solution Overview
Problem
High capacitance storage device modules face issues with voltage imbalance among cells, leading to accelerated aging and potential explosion, and existing solutions using connectors and harnesses are prone to errors, heat damage, and increased costs.
Innovation Solution
An energy storage device design that electrically connects terminals to a balancing circuit board without harnesses or connectors, using a substrate with a connection member and extension to provide current, and an insulation member to prevent electrical connection, allowing for direct connection of energy storage devices in series.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connectors and harnesses are used to electrically connect balancing circuit boards to high capacitance storage devices, then electrical connection is achieved, but connection errors, heat damage, and increased costs occur
Solution Approach 1:
The patent merges the connection functions by integrating the balancing circuit board directly with the connection members (bus bars or nuts) that connect high capacitance storage devices. This eliminates separate connectors and harnesses, reducing connection points and improving reliability while reducing structural complexity.
Solution Approach 2:
The balancing circuit board is designed to serve multiple functions: it provides cell balancing control and simultaneously acts as a connection member for electrical connection. This multi-functionality eliminates the need for separate connectors and harnesses, reducing both complexity and potential failure points.
2Power
If multiple connectors and harnesses are used for electrical connection, then current transmission is achieved, but heat generation and performance deterioration occur
Solution Approach 1:
The patent reduces the number of connection components by merging the balancing circuit board with the connection structure. This eliminates multiple connectors and harnesses that generate heat, thereby reducing overall heat generation while maintaining current transmission capability through the integrated structure.
3Power
If connectors and harnesses are used for electrical connection, then current supply to balancing circuit boards is achieved, but unit price increases
Solution Approach 1:
The patent integrates the balancing circuit board with the connection members, eliminating the need for separate connectors and harnesses. This reduction in component count directly lowers material costs and assembly complexity, thereby reducing the unit price while maintaining current supply capability.
Solution Approach 2:
The patent extracts and eliminates unnecessary components (connectors and harnesses) from the system. By removing these extra parts, the bill of materials is reduced, leading to lower manufacturing costs and improved ease of manufacture.
Data Source
Figure 1
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AI summary
Disclosed is an energy storage device, which comprises an external terminal having any one of positive and negative polarities and including a protrusion and a first terminal; a case having a polarity opposite to the external terminal and including an extension; a substrate disposed to surround an outer circumference of the protrusion of the external terminal through a hole formed at a center thereof; and a connection member located at an upper surface of the substrate and coupled to the first terminal of the external terminal, wherein the first terminal and the substrate are connected by means of the connection member, and the extension is connected to the substrate. Since a positive electrode and a negative electrode of the energy storage device are electrically connected to a substrate having a cell balancing function without a harness or any other member, it is possible to reduce the cost required for preparing the harness or any other member, and it is also possible to improve the economic feasibility and productivity of the energy storage device module by omitting the process of installing the harness or any other member.