Zigzag Battery Pack Layout for Dense Cell Bus Bar Connection
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Solution Overview
Problem
Existing battery packs face challenges in efficiently connecting multiple battery cells due to misalignment issues, which can lead to reduced packing density and increased dead spaces.
Innovation Solution
A battery pack design featuring a zigzag arrangement of battery cells in rows, with a bus bar having a zigzag shape to connect the cells in parallel, and a connection member to link the cells with the bus bar, ensuring efficient electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If battery cells are arranged in straight rows for easy manufacturing, then manufacturing precision is improved, but packing density deteriorates due to misalignment and dead spaces
Solution Approach 1:
The bus bar is designed with a curved shape that follows the zigzag arrangement of battery cells, allowing continuous electrical connection without sharp angles or straight segments. This curved configuration adapts to the compact cell layout while maintaining manufacturing feasibility through standard bending processes.
Solution Approach 2:
The battery cells are arranged in a zigzag pattern that utilizes both horizontal and vertical dimensions, transforming a simple linear arrangement into a two-dimensional compact layout. This dimensional transition allows tighter packing while the bus bar connects cells across both dimensions through its curved path.
2Quantity of substance
If battery cells are tightly packed to improve packing density, then volume efficiency is improved, but connection complexity increases due to misalignment
Solution Approach 1:
The curved bus bar design eliminates the need for complex angular connections or multiple connection points. By using a continuous curve, the connection structure simplifies while adapting to the zigzag cell arrangement, reducing manufacturing complexity despite the compact layout.
Solution Approach 2:
The bus bar's shape parameters are optimized to match the zigzag cell pattern, with curvature radius and segment lengths adjusted to accommodate cell misalignment. This parameter optimization allows the connection structure to adapt to compact arrangements without increasing complexity.
3Ease of manufacture
If a straight bus bar is used for simple manufacturing, then ease of manufacture is improved, but adaptability deteriorates due to inability to connect misaligned cells
Solution Approach 1:
The bus bar employs a curved configuration that can be manufactured using standard metal forming processes. The curvature provides adaptability to connect misaligned cells while remaining compatible with conventional fabrication methods, balancing ease of manufacture with connection flexibility.
Solution Approach 2:
The bus bar design incorporates flexible curvature that can adapt to different zigzag patterns and cell arrangements. This dynamic shape capability allows the same manufacturing process to produce bus bars suitable for various compact layouts, enhancing versatility without complicating production.
Data Source
AI summary
A battery pack includes: a plurality of battery cells arranged in rows that are parallel with a first axis, wherein the battery cells arranged in the rows adjacent to each other in a second axis crossing the first axis are forwardly or backwardly misaligned with each other with respect to the first axis; and a plurality of bus bars having a zigzag shape and forming a plurality of parallel modules by connecting corresponding ones of the battery cells arranged in the second axis in parallel.