Offset Battery Cells Zigzag Module Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery modules face safety issues due to close spacing of electrode terminals, leading to potential short circuits when connecting bus bars, especially in high-capacity applications like electric vehicles, where the risk of tool contact with adjacent terminals is high.
Innovation Solution
The battery module design features alternately offset battery cells in a zigzag configuration with bus bars extending at an angle (30-60 degrees) and includes spacers in open regions to maintain safety and efficiency, preventing short circuits by widening the terminal spacing and facilitating easier bus bar connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery cells are stacked closely to increase capacity, then the battery module achieves higher output voltage and current, but the electrode terminals become too close together causing safety risks of short circuits
Solution Approach 1:
The battery cells are arranged in an asymmetric zigzag pattern rather than a straight linear configuration. This asymmetric arrangement increases the spatial distance between electrode terminals of adjacent cells, reducing the risk of short circuits while maintaining high cell density for high capacity applications
Solution Approach 2:
The invention transitions from a one-dimensional linear stacking arrangement to a two-dimensional zigzag configuration. By utilizing the second spatial dimension perpendicular to the stacking direction, the design achieves both compact form factor and increased terminal spacing for safety
2Reliability
If electrode terminals are spaced far apart to prevent short circuits, then safety is improved, but the bus bar connection process becomes more complex and time-consuming
Solution Approach 1:
The zigzag arrangement is pre-designed into the battery module structure before assembly. This preliminary configuration ensures that even with increased terminal spacing, the bus bars can follow the same zigzag path and connect terminals efficiently without requiring complex routing or additional connection steps
3Volume of moving object
If battery cells are arranged in a compact linear configuration, then the module size is reduced, but heat dissipation becomes less effective
Solution Approach 1:
The zigzag arrangement distributes heat-generating cells across a two-dimensional area rather than concentrating them in a one-dimensional line. This spatial distribution improves thermal management by reducing localized heat accumulation while maintaining compact overall module dimensions
Solution Approach 2:
The zigzag configuration naturally segments the battery cells into alternating groups, creating regular open regions between cells. This segmentation facilitates heat dissipation pathways and improves thermal management efficiency
Data Source
AI summary
A battery module including a plurality of battery cells, the battery cells being stacked along a first direction, wherein the battery cells are alternately offset in a second direction, the second direction being perpendicular to the first direction.