Battery Module Failed-Cell Isolation via Terminal Bridging

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current battery modules require replacement when a single battery cell fails, leading to resource wastage and reduced efficiency due to the need for extensive replacement processes.

Innovation Solution

A battery module design where a conductive component connects the positive and negative electrode terminals of a failed battery cell, allowing it to be isolated without replacing the entire module, thereby simplifying maintenance and reducing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the entire battery module is replaced when a battery cell fails, then the battery module reliability is restored, but resource waste increases and maintenance time extends

Engineering Contradiction:

Improvebattery module reliabilityVSAvoidmaintenance time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The battery module is segmented into individual battery cells, allowing the failed cell to be isolated and handled separately from the functional cells. The housing includes a removable cover plate that enables access to the failed cell's electrode terminals for independent disconnection

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The failed battery cell is extracted from the operational circuit by disconnecting its electrode terminals using a conductive component. This allows the failed cell to be removed or isolated without affecting the remaining functional cells, eliminating the need to replace the entire module

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If the entire battery module is replaced when a battery cell fails, then the battery module reliability is restored, but resource waste increases

Engineering Contradiction:

Improvebattery module reliabilityVSAvoidresource waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The battery module structure is segmented to allow individual cell access and isolation. The housing with removable cover plates enables selective access to specific cells without disturbing others, facilitating partial maintenance rather than complete replacement

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Only the failed battery cell is discarded or isolated, while the functional cells are recovered and retained in the module. This selective replacement approach minimizes resource waste by keeping working components in use

Inventive Principle:

Principle #34Discarding and recovering

3Reliability

If the entire battery module is replaced when a battery cell fails, then the battery module reliability is restored, but maintenance complexity increases

Engineering Contradiction:

Improvebattery module reliabilityVSAvoidmaintenance complexity

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The module is divided into independently accessible cell compartments with removable cover plates. This segmentation allows maintenance personnel to access and service individual cells without disassembling the entire module, simplifying the repair process

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A conductive component serves as an intermediary mechanism for disconnecting the failed cell's electrode terminals. This intermediary device facilitates easy electrical isolation of the failed cell without requiring complex disconnection procedures

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enables efficient maintenance by isolating the failed cell, preventing it from affecting the circuit, reducing maintenance time, and maintaining the battery module's functionality and capacity without replacing the entire module.

Implementation Method 1

a conductive component, where the conductive component is connected to a positive electrode terminal and a negative electrode terminal of the failed battery cell

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS11799142B2Battery module, device, and failure handling method for failed battery cell

Publication Date: 2023.10.24 CONTEMPORARY AMPEREX TECHNOLOGY (HONG KONG) LIMITED

AI summary

This application relates to a battery module, a device, and a failure handling method for a failed battery cell. The battery module includes: battery cells, where each battery cell includes a housing, a top cover, and an electrode assembly, the housing is connected to the top cover, the housing includes a first accommodation cavity, the electrode assembly is located inside the first accommodation cavity, the top cover is provided with a positive electrode terminal and a negative electrode terminal, and the battery cells further include a failed battery cell; and a conductive component, connected to the positive electrode terminal and the negative electrode terminal of the failed battery cell. After being connected to the electrode terminals, the conductive component does not occupy space outside the failed battery cell, improving safety of the battery module.