Battery Module Connector for Rapid Cell Replacement
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Solution Overview
Problem
Conventional methods for connecting battery cells, such as welding or bolting, are prone to weld defects and require significant time and effort for repair or replacement, making it difficult to field-repair or replace damaged cells in battery modules.
Innovation Solution
A connector system with a main body, push members, and a core member, facilitated by a movement mechanism, allows for easy electrical interconnection and disconnection of battery cells, enabling quick replacement of defective cells by compressively sandwiching electrode leads between conductive contact portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding method is used to connect battery cells, then electrical connection is achieved, but weld defects may occur and field repair is not possible
Solution Approach 1:
The connector is divided into separable components (first connector part on one battery cell, second connector part on another battery cell) that can be independently handled. This segmentation allows the connection to be made in sections rather than requiring complete disassembly, enabling field repair of individual cells without affecting the entire battery module.
Solution Approach 2:
The connector employs a dynamic pressing mechanism where pressing members can apply force to maintain electrical contact. This dynamic capability allows the connection to be adjusted and maintained without permanent fixation, enabling easy disconnection and reconnection for field repair purposes while ensuring reliable electrical contact during operation.
2Strength
If bolting method is used to connect battery cells, then mechanical connection is achieved, but significant time is needed for disassembly and reassembly
Solution Approach 1:
The connector is segmented into first and second connector parts that are separately attached to different battery cells. This segmentation eliminates the need for complete module disassembly, allowing rapid connection and disconnection of individual cells, thereby significantly reducing repair time while maintaining mechanical strength through dedicated pressing members.
Solution Approach 2:
The pressing members are pre-configured within the connector structure to automatically apply pressing force upon assembly. This preliminary action ensures that mechanical strength is achieved immediately upon connection without requiring additional tightening or adjustment steps, enabling quick field repair operations.
3Reliability
If conventional connection methods are used, then battery cells are electrically connected, but replacement of damaged cells requires disassembling the entire module
Solution Approach 1:
The connector system is divided into independent first and second connector parts that attach to individual battery cells. This segmentation enables the replacement of single damaged cells by simply disconnecting and reconnecting the respective connector parts, without requiring disassembly of the entire battery module, thereby greatly improving ease of operation for maintenance purposes.
Solution Approach 2:
The connector acts as an intermediary component between battery cells, providing a standardized interface that facilitates easy connection and disconnection. This intermediary structure enables rapid cell replacement by serving as a removable link in the electrical connection chain, maintaining system reliability while dramatically simplifying replacement operations.
Data Source
AI summary
A connector has a conductive main body with contact portions to compress a plurality of electrode leads of battery cells. The connector has two push members each with a level surface and an inclined surface on opposing sides of each push member, such that each push member is movable and spaced between the contact portions. and compress the plurality of electrode leads with a corresponding contact portion. The connector has a core member with a second inclined surface, such that the core member is movable in a parallel direction to the contact portion, is located between the two push members, and compresses the two push members against the conductive main body. The connector has a movement mechanism to move the core member in the parallel direction and compress the plurality of electrode leads between the conductive main body and the push members. A battery module may contain the connector.