Battery Module Bypass Sheet for Failed Cell Isolation
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Solution Overview
Problem
Existing battery modules fail when a single battery unit malfunctions, causing the entire circuit to fail and requiring costly and inefficient replacement of the entire module, which wastes resources and disrupts battery balance.
Innovation Solution
A battery module design featuring a connecting sheet with breakage guide portions that allows easy disconnection of failed units, using an electroconductive part to bypass the failed unit, maintaining the circuit with adjacent unfailed units, thus preventing the failed unit from participating in charging and discharging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a battery unit fails in a series-connected battery module, then the entire circuit fails and the whole module must be replaced, but this results in high maintenance cost and resource waste
Solution Approach 1:
The connecting sheet is divided into multiple detachable connection portions, each connecting adjacent battery units. When a battery unit fails, only the specific connection portions related to that unit need to be detached, rather than replacing the entire module. This segmentation enables partial maintenance and reduces waste.
Solution Approach 2:
The failed battery unit is extracted from the series circuit by detaching the connection portions, allowing the remaining functional units to continue operating. This extraction principle enables the system to maintain functionality despite individual unit failures.
2Reliability
If the entire battery module is replaced when one unit fails, then the circuit reliability is maintained, but the maintenance time and productivity are severely impacted
Solution Approach 1:
The connecting sheet is segmented into multiple independent connection portions that can be detached separately. This allows maintenance personnel to quickly remove only the failed unit's connections rather than disassembling the entire module, significantly improving maintenance efficiency while preserving circuit reliability.
Solution Approach 2:
The connecting sheet is designed with pre-formed connection portions that facilitate quick detachment. This preliminary design of the connection structure enables rapid maintenance operations without requiring complex disassembly procedures.
3Strength
If the connecting sheet is made strong and durable, then the structural strength is improved, but the ease of disassembly for maintenance is reduced
Solution Approach 1:
The connecting sheet is divided into multiple connection portions with different structural characteristics. The main body maintains high strength for durability, while the connection portions are designed with weaker, easily detachable structures (such as adhesive bonds or mechanical clips) that allow simple disassembly for maintenance.
Solution Approach 2:
Different regions of the connecting sheet have different structural qualities: the main body uses strong, durable materials and structures for overall strength, while the connection portions use weaker, easily detachable designs for maintenance ease. This local differentiation resolves the contradiction between strength and ease of disassembly.
Data Source
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AI summary
Embodiments of the present application relate to a battery module, a battery pack, a device and a failure processing method. The battery module includes: a plurality of battery units for series connection, where after the battery module fails, the plurality of battery units include a failed battery unit and at least one unfailed battery unit adjacent to the failed battery unit; a connecting sheet, used to connect the plurality of battery units in series, where the connecting sheet is provided with at least one breakage guide portion for guiding the connecting sheet to break and form a first part and a second part which are arranged separately, where the first part is used to be connected to the at least one unfailed battery unit and the second part is used to be connected to the failed battery unit; and an electroconductive part, used to be connected to the first part, so that current bypasses the failed battery unit and the battery module resumes work. In the embodiments of the present application, the connecting sheet is provided with the breakage guide portion, so that the connecting sheet is easier to break, thereby the unfailed battery unit can be conveniently disconnected from the failed battery unit, and the failure processing efficiency is improved.