Stacked Battery Array Assembly With Insulated Bus Bars
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Solution Overview
Problem
Existing battery assemblies are cumbersome, have complex structures, and lack scalability and energy density, making them unsuitable for efficient integration into energy storage systems.
Innovation Solution
A battery assembly design featuring stacked battery arrays with insulated bus bars and a simplified frame structure, allowing for stable fixation and electrical insulation of battery cells, reducing parts, and enabling easy expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional battery assembly structures are used, then battery cells can be accommodated, but the structure becomes cumbersome and complex with increased number of parts
Solution Approach 1:
The battery assembly is divided into multiple battery arrays, each independently accommodated within the case. This segmentation allows for modular organization of battery cells, reducing overall structural complexity while maintaining stable fixation through standardized array configurations
Solution Approach 2:
Multiple battery arrays are combined within a single case structure, with bus bars integrating electrical connections across arrays. This merging reduces the number of separate components needed while ensuring stable fixation through the unified case enclosure
2Reliability
If more parts are used for stable fixation, then battery cells are securely fixed, but the number of parts increases and structure becomes more complex
Solution Approach 1:
The case structure serves multiple functions simultaneously: it accommodates battery arrays, provides structural support for fixation, and integrates bus bar mounting. This multi-functionality reduces the number of separate parts needed while ensuring stable fixation of battery cells
Solution Approach 2:
The bus bars are designed to provide both electrical connection and structural support functions. By making the bus bars self-supporting within the case, additional fixation components are eliminated, reducing part count while maintaining fixation stability
3Quantity of substance
If traditional battery assembly design is used, then battery cells can be connected, but energy density is reduced due to complex structure and more parts
Solution Approach 1:
Battery cells are arranged in stacked configurations within the case, utilizing vertical space more efficiently. This dimensional arrangement increases the quantity of battery cells that can be accommodated without proportionally increasing structural complexity, thereby improving energy density
4Quantity of substance
If battery arrays are stacked closely for better space utilization, then energy density improves, but electrical insulation between arrays becomes more difficult
Solution Approach 1:
Insulation components are positioned between stacked battery arrays to prevent electrical contact. These intermediary elements enable close stacking for space efficiency while maintaining necessary electrical insulation, thus improving energy density without compromising safety
Data Source
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AI summary
Disclosed is a battery assembly. The battery assembly includes a case providing an inner space; a first battery array accommodated inside the case and including a plurality of battery cells stacked in a left and right direction; a second battery array accommodated inside the case and including a plurality of battery cells stacked in the left and right direction, the second battery array being stacked with the first battery array in the left and right direction; a first bus bar electrically connected to a front side of the first battery array and electrically insulated from the second battery array; and a second bus bar electrically connected to a front side of the second battery array and electrically insulated from the first battery array.