Battery Module Cell Biasing and Tension Rods for Replaceable Cells
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Solution Overview
Problem
Battery packs face issues such as thermal runaway, difficulty in disassembly, high weight, and low cell density, making them hazardous and impractical for reuse or replacement.
Innovation Solution
A battery pack module design featuring a module housing with a cell chamber, cooling fluid, bus bars for series and parallel connections, cell biasing members, and tension rods for clamping, allowing for easy cell replacement and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery packs use traditional sealing and structural designs, then thermal safety may be improved, but disassembly difficulty increases and cell replacement becomes impractical
Solution Approach 1:
The battery pack is divided into modular sections with individual cell compartments. Each cell can be accessed and replaced independently through the modular housing structure, allowing maintenance without disassembling the entire pack while maintaining thermal safety through compartmentalization.
Solution Approach 2:
A tension rod mechanism with biasing members acts as an intermediary system between the housing and cells. This mechanism provides controlled access and retention, enabling easy cell removal and installation while maintaining secure engagement and thermal safety during operation.
2Manufacturing precision
If battery packs use rigid fixed structures, then manufacturing precision may be improved, but adaptability for cell replacement decreases
Solution Approach 1:
The structure transitions from rigid fixed to dynamically adjustable through tension rods with biasing members. The biasing members provide controlled compliance that maintains precise engagement forces while allowing cells to be easily installed and removed, combining manufacturing precision with replacement adaptability.
3Strength
If battery packs use traditional engagement mechanisms, then structural strength may be improved, but device complexity increases
Solution Approach 1:
The complex multi-component engagement mechanisms are extracted and replaced with a simplified tension rod system. The tension rods with biasing members provide sufficient structural strength through a single integrated component, reducing overall device complexity while maintaining engagement strength.
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
Enhances safety by preventing thermal runaway, facilitates easy cell disassembly and replacement, and improves cell density and weight efficiency.
Implementation Method 1
the module housing defines a cell chamber for holding the plurality of cells and a quantity of a cooling fluid
Implementation Method 2
at least one cell biasing member that is positioned to urge the cells and the bus bars into engagement with one another with at least a selected engagement force
Implementation Method 3
at least one of the first and second connections is a threaded connection, such that the second end member is rotatable by a tool until a selected torque is reached
Data Source
AI summary
A battery pack is provided and includes a battery pack housing defining a pair of side walls. and a plurality of modules positioned in the battery pack housing in a row along the side walls. Each of the modules includes a module housing that extends between the side walls. Each of modules contains a first plurality of cells that are all electrically connected to one another. and a second plurality of cells that are all electrically connected to one another, and which are electrically isolated from the first plurality of cells. Cell biasing members bias the cells toward the busbar for improved connectivity and tension rods prevent deformation of the modules from thermal expansion.