Battery Module Cell Replacement Mechanism
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Solution Overview
Problem
Existing battery modules require the entire unit to be discarded when one or more battery cells become defective, as replacing individual cells is not easily feasible.
Innovation Solution
A battery module design featuring a connection member with an insertion groove and hinge portion, allowing for easy removal and replacement of defective cells by compressing or extending elastic members to move engaging parts between positions, facilitating the disconnection of defective cells from the bus bar and cell cap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery cells are connected in parallel with welding to nickel tabs, then electrical connection reliability is improved, but ease of repair deteriorates because the entire battery module must be discarded when one cell is defective
Solution Approach 1:
The connection member is divided into separate components: a bus bar portion, a cell cap portion, and an elastic member. This segmentation allows the cell cap portion to be independently removed from defective cells while maintaining connection to functional cells through the bus bar, enabling selective cell replacement without discarding the entire battery module.
Solution Approach 2:
The elastic member provides dynamic, reversible connection through compression and extension. During normal operation, the elastic member maintains firm electrical connection. During replacement, the elastic member can be compressed to release the cell cap portion, allowing easy removal of defective cells while preserving the overall module structure.
2Stability of the object's composition
If a rigid connection structure is used between cell caps and bus bars, then connection stability is improved, but ease of operation deteriorates because replacement requires complex disassembly
Solution Approach 1:
The elastic member transforms the rigid connection into a dynamic one that adapts to operational needs. Under normal conditions, it provides stable connection through elastic force. During maintenance, it allows easy disconnection through simple compression, eliminating the need for complex disassembly tools or procedures.
Solution Approach 2:
The connection state changes from firmly connected to disconnected through parameter change (compression of elastic member). This allows the same connection structure to provide both stability during operation and ease of replacement during maintenance by simply changing the compression state of the elastic member.
3Reliability
If the entire battery module is discarded when one cell is defective, then reliability is maintained by ensuring all cells are functional, but loss of substance worsens because working cells are wasted along with defective ones
Solution Approach 1:
The battery module is segmented into replaceable cell units with independent cell cap portions. This allows only the defective cell and its associated cell cap portion to be removed, while the remaining functional cells and the bus bar structure are preserved and reused, significantly reducing material waste.
Solution Approach 2:
Instead of discarding the entire battery module, the invention enables recovery and reuse of the bus bar, connection members, and functional cells. Only the defective cell and its minimal associated components are discarded, while the majority of the module is recovered and continues to function.
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
Enables the cost-effective and efficient replacement of defective battery cells within a battery module, extending the life of the module and reducing waste by allowing only the faulty cells to be replaced.
Implementation Method 1
an elastic member mounted in the inserting portion. The engaging parts may be configured to move towards and away from each other along the second direction due to compression and extension, respectively, of the elastic member
Data Source
AI summary
A battery module includes a plurality of battery cells, each of the battery cells including an electrode terminal; a cell cap coupled to an electrode terminal of one of the battery cells; a bus bar coupling adjacent ones of the battery cells to each other in parallel; and a connection member coupling the cell cap and the bus bar to each other.