Modular Battery Connector Assembly for Scalable Power Systems
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery cell stack connector assemblies require multiple carriers for different numbers of cells, leading to inefficiencies in electrical connection and increased costs due to the need for customized carriers for varying power requirements and configurations.
Innovation Solution
A modular busbar connector assembly comprising a plurality of busbar modules with module frames and attached busbars, allowing for flexible and standardized electrical connection of battery cells by aligning module axes and mating connectors to form a continuous connector axis, enabling easy adaptation to different cell stack configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple customized carriers are used for different numbers of battery cells, then the battery assembly can accommodate varying power requirements and configurations, but the device complexity and manufacturing costs increase
Solution Approach 1:
The patent applies universality by designing a single standardized carrier that can accommodate different numbers and configurations of battery cells through adjustable connector assemblies. The carrier frame includes multiple mounting positions and the connector assembly can be configured in various series/parallel arrangements, allowing one carrier design to serve multiple battery configurations rather than requiring separate customized carriers for each configuration.
Solution Approach 2:
The patent applies segmentation by dividing the connector assembly into modular components including individual busbar connectors, cell holders, and mounting brackets that can be independently configured. This modular approach allows the same carrier to be adapted for different battery cell counts by selectively assembling and configuring the modular connector components rather than requiring entirely different carrier designs.
2Adaptability or versatility
If multiple customized carriers are used for different battery configurations, then various power requirements can be met, but the manufacturing costs increase
Solution Approach 1:
The standardized carrier design with universal mounting features and configurable connectors allows a single carrier type to be manufactured and used across multiple battery configurations, eliminating the need to manufacture multiple specialized carrier variants. This reduces tooling costs, inventory requirements, and manufacturing complexity while maintaining the ability to accommodate different power requirements through connector configuration rather than carrier redesign.
Solution Approach 2:
The patent utilizes parameter changes by allowing the electrical configuration (series/parallel connections) to be varied through connector assembly rather than changing the physical carrier structure. This enables different power outputs and voltage configurations to be achieved by reconfiguring the electrical connections on the same carrier, reducing manufacturing costs associated with producing multiple carrier types with different structural parameters.
3Reliability
If standardized battery cells are used with known dimensions, then the power requirements can be reliably met, but the connector assembly complexity increases to accommodate different cell stack configurations
Solution Approach 1:
The patent applies dynamics by designing the connector assembly with adjustable and reconfigurable elements that can adapt to different cell stack configurations. The connector positions, busbar arrangements, and mounting configurations can be dynamically adjusted to match the specific power requirements while maintaining reliable electrical connections, rather than requiring complex fixed-structure connectors for each possible configuration.
Solution Approach 2:
The connector assembly is segmented into independent, standardized modules that can be selectively assembled to match different battery cell configurations. This modular segmentation allows the connector structure to be simplified for each specific application while maintaining the ability to accommodate various power requirements through selective module assembly, rather than requiring a single complex universal structure.
Data Source
AI summary
A battery cell stack connector assembly includes a plurality of busbar modules. Each of the busbar modules has a module frame with a first side with a first connector and a second side with a second connector. Each module frame defines a module axis that extends from the first side to the second side. Each of the busbar modules also includes a busbar attached to the module frame. The plurality of busbar modules are connected to form a connector frame that defines a connector axis that extends from a first assembly side to a second assembly side. The module axes of the plurality of busbar modules are aligned with the connector axis. Also, the first connectors and second connectors are adapted so that each of the plurality of module frames is mated with and attached to respective adjacent module frames.