Power Storage Modules with Segmented Conductive Trays
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Solution Overview
Problem
Traction battery systems in hybrid and electric vehicles face challenges in reducing thickness and preventing short circuits when liquid enters, leading to potential sparks and ignition due to high voltage and current flow between bus bars and metal frames.
Innovation Solution
A power storage system with power storage modules aligned horizontally and cells layered perpendicularly, using conductive trays and resin plates to divide modules into groups, reducing the risk of short circuits by increasing resistivity and controlling discharge current, and employing bus bar projections to manage voltage and current flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If power storage modules are horizontally aligned with cells layered vertically to reduce height, then height requirement is satisfied, but risk of short circuit via liquid between bus bars increases
Solution Approach 1:
The power storage system is divided into multiple groups by conductive trays positioned between the power storage modules and the frame. Each group contains a subset of power storage modules, and the trays are electrically connected to create segmented zones. This segmentation limits the propagation path of liquid, ensuring that even if liquid enters, it can only cause short circuits within the same group rather than across the entire system.
Solution Approach 2:
Conductive trays are introduced as intermediary elements between the power storage modules and the metal frame. These trays serve as controlled conductive paths that are electrically connected in a specific pattern, mediating the electrical connection while limiting liquid flow paths. The trays act as a barrier that guides liquid containment within specific zones.
2Reliability
If liquid enters between bus bars connected to bottom cells, then short circuit occurs via liquid and metal frame, but heavy current flow generates sparks and ignition
Solution Approach 1:
By dividing the power storage system into multiple groups using conductive trays, the potential short circuit path is segmented into smaller sections. This limits the voltage difference across any single liquid junction to that of adjacent modules only, rather than the full system voltage, thereby reducing the energy available to generate sparks or ignition.
Solution Approach 2:
The conductive trays are pre-positioned and electrically connected in a controlled manner to create predetermined low-resistance paths. When liquid enters, the current follows these pre-established paths through the trays rather than creating uncontrolled high-current paths through the metal frame, preventing harmful sparks and ignition.
3Power
If conventional horizontal alignment with side surfaces downward is used, then high voltage output is achieved, but thickness reduction requirement cannot be met
Solution Approach 1:
The patent transitions from conventional horizontal alignment (occupying horizontal space) to vertical layering of cells within modules (occupying vertical space). This dimensional reorganization allows the system to achieve the required voltage output through series connection while reducing the horizontal footprint and overall thickness to meet vehicle installation requirements.
Data Source
AI summary
A power storage system includes a plurality of power storage modules each including a plurality of cells that is layered perpendicularly to an installation plane and is electrically connected dries. The plurality of power storage modules is mounted on a frame. A plurality of conductive trays is aligned horizontally between the frame and the plurality of power storage modules and horizontally divides the plurality of power storage modules into a plurality of groups.