Battery Cell Pack Assembly for Selective Cell Replacement
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Solution Overview
Problem
Traditional methods of assembling electrochemical cells in battery modules do not allow for selective removal and replacement of individual defective cells, leading to increased costs and environmental impact during maintenance and recycling.
Innovation Solution
A cell assembly device with a pusher mechanism that slides on a support base, allowing cells to be translated and wedged into place, enabling selective extraction and replacement of faulty cells without disturbing the rest of the module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If cells are fixed using traditional methods (screwing or gluing onto support base), then mechanical stability is achieved, but selective removal and replacement of individual defective cells becomes impossible
Solution Approach 1:
The invention divides the fixation system into modular components: individual cells can be independently removed from the module by detaching them from the common support base, while the remaining cells stay fixed. This segmentation enables selective replacement of defective cells without affecting the entire module structure.
Solution Approach 2:
The fixation system transitions from a static, permanent attachment (screwing/gluing) to a dynamic, reversible connection. Cells can be moved between fixed and removable states, allowing maintenance operations while maintaining structural integrity during normal operation.
2Ease of manufacture
If traditional fixing methods are used, then assembly simplicity is maintained, but maintenance costs increase due to replacement of entire modules
Solution Approach 1:
The module is segmented into independently replaceable cell units mounted on a shared support base. This allows replacement of only defective cells rather than entire modules, reducing maintenance costs while keeping the assembly process simple through standardized mounting interfaces.
Solution Approach 2:
Instead of discarding or replacing entire modules when one cell is defective, the invention enables recovery and retention of functional cells. Only the defective cell is removed and replaced, while working cells remain in service, reducing waste and maintenance expenses.
3Device complexity
If modules with multiple cells are used, then battery pack structure is simplified, but recycling efficiency decreases due to processing of all cells including working ones
Solution Approach 1:
The battery pack structure uses a common support base that holds multiple cells in a modular arrangement. This segmentation enables easy separation of individual cells from the module, allowing recyclers to process only defective cells while recovering and reusing functional cells, thereby improving recycling efficiency without complicating the overall pack structure.
4Stability of the object's composition
If cells are assembled into modules, then mechanical support and organization are provided, but adaptability for individual cell replacement is lost
Solution Approach 1:
The module structure is segmented into independently replaceable cell units mounted on a shared support base. This design maintains the organizational benefits of modular assembly while enabling individual cell replacement, as each cell can be detached and replaced without affecting the structural stability of the remaining module.
Solution Approach 2:
The fixation system allows dynamic reconfiguration where cells can transition between fixed operational states and removable replacement states. The support base provides stable structural support while accommodating the adaptability needed for individual cell maintenance and replacement.
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
Facilitates battery maintenance by allowing easy removal of defective cells, reduces economic costs, and simplifies recycling by minimizing the number of cells processed, thus reducing environmental impact.
Implementation Method 1
a pusher (1) housed in a sliding manner in a housing (2) mounted laterally on at least a first side (E1) of the base (E) and intended to come into bearing contact, under the action of at least one actuator (3), against a first stud (11) mounted at the lower part of the shell of each of said cells to move said shell in translation on the base
Implementation Method 2
the device of the invention comprises a stop (4) mounted on a second side (E2) of the base opposite the first side and intended to ensure the end of the translational travel and the wedging of the cell shell
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a device for assembling a series of cells in a battery pack, each of said cells being provided with a shell (C) forming an integral part of said cell and resting on a support base (E) arranged at the lower part of the pack, characterized in that it comprises a pusher (1) housed in a sliding manner in a housing (2) mounted laterally on at least a first side (E1) of the base and intended to come into bearing contact, under the action of at least one actuator (3), against a first stud (11) mounted at the lower part of the shell of each of said cells to move said shell in translation on the base.