Sliding Bus Bar Battery Assembly with Insulating Frames
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Solution Overview
Problem
Lithium secondary batteries are vulnerable to thermal events and swelling, which can lead to physical damage and increased risk of thermal chain reactions, especially in crowded battery modules or packs, posing safety hazards.
Innovation Solution
A battery assembly design featuring a case with stacked battery cells, a sliding bus bar system along rails, and stoppers to prevent electrical shorts and limit movement, combined with an insulating frame and terrace supports to minimize damage during swelling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a plurality of battery cells are crowded in a small space to increase capacity, then productivity and energy density are improved, but the risk of thermal events and thermal chain reactions increases
Solution Approach 1:
The battery module is divided into multiple battery cell groups, with each group independently accommodated in its own case. This segmentation creates physical separation between battery cells, preventing thermal chain reactions while maintaining high energy density through optimized spatial arrangement of multiple groups within the module.
Solution Approach 2:
Insulating frames and insulating members are introduced as intermediary elements between battery cells and cases. These insulating components act as thermal barriers, reducing heat transfer between adjacent battery cells while maintaining the compact structure needed for high energy density.
2Volume of stationary object
If battery cells are stacked closely to reduce module size, then volume efficiency is improved, but vulnerability to thermal propagation increases
Solution Approach 1:
The design transitions from two-dimensional close stacking to three-dimensional structured arrangement with vertical and horizontal separation. Insulating frames are positioned at multiple levels (first, second, third insulating frames at different heights) creating dimensional separation that reduces thermal propagation risk while optimizing volume utilization.
Solution Approach 2:
Insulating members and elastic members are pre-installed between battery cells and cases as protective cushioning elements. These components are positioned in advance to absorb thermal expansion, mechanical stress, and prevent direct thermal contact between battery cells, thereby preventing thermal propagation before it can occur.
3Productivity
If battery cells are tightly arranged to maximize capacity, then energy density is improved, but damage from swelling increases thermal event risk
Solution Approach 1:
Elastic members are pre-installed between adjacent battery cells to provide cushioning against swelling. These elastic components can deform to accommodate volume changes in battery cells during charging cycles, preventing mechanical damage from swelling while maintaining tight arrangement for high capacity.
Solution Approach 2:
The insulating frames and protective structures use flexible materials that can adapt to battery cell dimensional changes. This flexibility allows the structure to accommodate swelling without transmitting damaging forces to the battery cells, thereby protecting capacity while managing swelling effects.
Data Source
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AI summary
Disclosed is a battery assembly. The battery assembly includes a case providing an inner space; a plurality of battery cells accommodated in the case and stacked in a left and right direction; a rail provided in the case and extending in the left and right direction; and a bus bar configured to slide along the rail and electrically connected to the plurality of battery cells.