Stackable Battery Bussing With Integrated Cell Interconnects
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Solution Overview
Problem
Existing battery systems face challenges in safely and compactly provisioning and re-provisioning high voltage and high capacity battery modules, particularly in large, high-energy density applications, due to wiring complexity, safety concerns, and lack of flexibility in configuration.
Innovation Solution
A Stackbatt system that uses copper sleeves for interconnecting battery cells with male terminals, allowing for safe and compact stacking with terminator connectors to control voltage and amperage, and includes an insulation shroud and intumescent materials for safety, along with optional sensors for monitoring heat, voltage, and amperage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple batteries are connected in parallel or series with suitable wiring to achieve greater power, then power output is improved, but wiring complexity and safety considerations worsen
Solution Approach 1:
The patent combines multiple battery cells into a single integrated housing with internal bussing structures that merge the electrical connections. The housing itself acts as a container that integrates mechanical support, electrical connection, and safety features, eliminating the need for external wiring harnesses and connectors between cells.
Solution Approach 2:
The patent introduces a bussing structure as an intermediary component that facilitates electrical connections between battery cells. This bussing structure serves as a mediator that simplifies the connection process by providing pre-configured electrical pathways, reducing the complexity of direct wiring between cells.
2Power
If multiple batteries are connected in parallel or series with suitable wiring to achieve greater power, then power output is improved, but safety considerations worsen
Solution Approach 1:
The patent incorporates safety features beforehand into the battery assembly design. Thermal runaway barriers and current interruption mechanisms are pre-installed within the housing structure, providing protective cushioning against potential failures before they occur. The design anticipates failure modes and builds in protective measures.
Solution Approach 2:
The bussing structure serves as an intermediary that includes built-in safety features such as current interruption capabilities and thermal management pathways. This mediator component provides safety functions that protect the entire battery assembly from individual cell failures.
3Adaptability or versatility
If a separate bus is used to connect battery modules together, then modularity is improved, but simplicity and flexibility are reduced
Solution Approach 1:
The patent merges the bus structure with the battery housing into a single integrated component. The housing serves dual purposes: mechanical containment and electrical connection. This combination eliminates the need for separate external bussing components while maintaining the ability to connect multiple battery modules together.
Solution Approach 2:
The battery housing is designed with multi-functionality, serving as both the mechanical container and the electrical connection interface. The housing includes integrated bussing structures that provide universal connection capabilities, allowing the same housing design to work in various module configurations without requiring additional external components.
Data Source
AI summary
A stackable electrical-energy bussing system, for energy storage battery cells constructed according to the present invention includes a battery cell case having electrically conductive terminals that fit together with the terminals of a similar battery cell in order to enable multiple battery cells to be interconnected physically and electrically by stacking them atop each other. A Stackbatt bussing system housing contains the electricity-producing elements for each cell, connected from each opposing side. Preferably, the battery cell includes at least two such male terminals in spaced-apart relationship on the top side of the cell case, and at least two such female bus tubes that mate and receive with a spaced-apart relationship on both sides of the Stackbatt bussing system. Preferably, a multi-cell battery bussing system constructed to the invention includes multiple battery cells as described above, stacked when desired to achieve desired battery voltage for series and or parallel configurations.