Battery Cell Connector Assembly for Fast Field Replacement

Solution Overview

Problem

Conventional energy storage systems lack efficient and automated methods for fast engaging and disengaging battery cells, making field replacement difficult and time-consuming, especially in configurations like cylindrical, prismatic, and pouch cells, which requires significant investment in equipment and poses reliability concerns.

Innovation Solution

The implementation of a connecting/disconnecting device on a printed circuit board assembly (PCBA) that allows for quick electrical interconnection, routing, voltage sensing, and temperature sensing, enabling easy field replacement of battery cells without the need for expensive components, using mechanisms like metal tabs, quick connect components, and pre-welded pins.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional welding or screw connections are used to connect battery cells to PCBA, then electrical interconnection is achieved, but field replacement of cells becomes extremely difficult and time-consuming

Engineering Contradiction:

Improveelectrical interconnection reliabilityVSAvoidfield replacement ease

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The connection system is divided into separable components: a connector assembly on the PCBA side and corresponding connectors on the battery cell side. This segmentation allows the cell to be disconnected and replaced without affecting other cells or requiring complex disassembly of the entire battery module, thus enabling easy field replacement while maintaining reliable electrical connection during operation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connection system transitions from a static permanent connection (welding/screws) to a dynamic reversible connection. The connector assembly includes movable components such as spring-loaded contacts and detachable coupling mechanisms that allow the connection to be easily made and broken, facilitating rapid field replacement while ensuring stable electrical contact during normal operation.

Inventive Principle:

Principle #15Dynamics

2Reliability

If spot welding or screw connections are used for battery cells, then electrical connection is established, but the process becomes complex and difficult to automate

Engineering Contradiction:

Improveelectrical connection stabilityVSAvoidassembly automation capability

Core Design Contradiction:

ReliabilityVSExtent of automation

Solution Approach 1:

The connection system is divided into separable components: a connector assembly on the PCBA side and corresponding connectors on the battery cell side. This segmentation allows the cell to be disconnected and replaced without affecting other cells or requiring complex disassembly of the entire battery module, thus enabling easy field replacement while maintaining reliable electrical connection during operation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connection system transitions from a static permanent connection (welding/screws) to a dynamic reversible connection. The connector assembly includes movable components such as spring-loaded contacts and detachable coupling mechanisms that allow the connection to be easily made and broken, facilitating rapid field replacement while ensuring stable electrical contact during normal operation.

Inventive Principle:

Principle #15Dynamics

3Reliability

If conventional connection methods are used for battery cells, then electrical interconnection is achieved, but fast disengagement for field replacement is not enabled

Engineering Contradiction:

Improveelectrical interconnection reliabilityVSAvoidfield replacement time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The connection system is divided into separable components: a connector assembly on the PCBA side and corresponding connectors on the battery cell side. This segmentation allows the cell to be disconnected and replaced without affecting other cells or requiring complex disassembly of the entire battery module, thus enabling easy field replacement while maintaining reliable electrical connection during operation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connection system transitions from a static permanent connection (welding/screws) to a dynamic reversible connection. The connector assembly includes movable components such as spring-loaded contacts and detachable coupling mechanisms that allow the connection to be easily made and broken, facilitating rapid field replacement while ensuring stable electrical contact during normal operation.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS20240079733A1Fast engaging-disengaging connectors for cell-to-system battery design

Publication Date: 2024.03.07 ENPHASE ENERGY INC

AI summary

The present disclosure provides an energy storage system. For example, an energy storage system comprises a printed circuit board assembly configured to connect to a chassis of the energy storage system and a battery cell comprising a connecting/disconnecting device configured to engage a corresponding connecting/disconnecting device on the printed circuit board assembly for providing at least one of electrical interconnection, routing, voltage sensing, or temperature sensing.