Battery Module Connector Segmentation for Failed Cell Bypass
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Solution Overview
Problem
When a battery unit in a battery module fails, the entire circuit fails, leading to normal operation issues, and existing methods like replacing the entire module or module are inefficient and resource-intensive.
Innovation Solution
A battery module design with a connecting sheet featuring breakage guide portions allows easy disconnection of failed units by forming separate first and second parts, using an electroconductive part to bypass the failed unit, and reconnecting unfailed units, thereby maintaining circuit functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire battery module is replaced when a battery unit fails, then the circuit functionality is restored, but resource waste increases and processing time is extended
Solution Approach 1:
The connecting sheet is segmented into a first part and a second part through breakage guide portions, allowing selective disconnection of the failed battery unit while maintaining connection of functional units. This enables partial replacement rather than complete module replacement, reducing processing time and resource waste.
Solution Approach 2:
The failed battery unit is extracted from the circuit by disconnecting only its associated connecting sheet portion (second part), while the rest of the battery module remains operational. This extraction approach restores circuit functionality without requiring replacement of the entire module.
2Reliability
If the entire battery module is replaced when a battery unit fails, then the circuit functionality is restored, but resource waste increases
Solution Approach 1:
The connecting sheet is divided into separable parts through breakage guide portions, enabling removal of only the failed battery unit's connection portion. This segmentation allows functional battery units to be retained and reused, significantly reducing resource waste compared to complete module replacement.
Solution Approach 2:
Only the failed battery unit and its associated connecting sheet portion (second part) are discarded, while the functional battery units and the first part of the connecting sheet are recovered and retained for continued use. This selective discarding approach minimizes resource waste.
3Strength
If the connecting sheet is made strong and durable, then connection reliability is improved, but ease of disconnection for failure processing deteriorates
Solution Approach 1:
The connecting sheet has different structural qualities at different locations: the main body maintains high strength for reliable connection, while the breakage guide portions are designed with reduced strength or pre-defined fracture paths to enable easy disconnection when needed. This local differentiation resolves the contradiction between durability and ease of repair.
Solution Approach 2:
The breakage guide portions are pre-designed with features such as reduced thickness, notches, or predetermined fracture lines that facilitate easy breaking when disconnection is required. This preliminary preparation allows the connecting sheet to be both strong during normal operation and easily disconnectable during maintenance.
Data Source
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.