Modular Battery Pack Cartridges for Weld-Free Cell Replacement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery packs for home energy storage systems (ESS) are difficult to maintain as individual battery cells cannot be replaced without replacing the entire module, due to their welded structure, leading to increased costs and inefficiencies.
Innovation Solution
A modular battery pack design featuring a casing, cartridges, and a lead jig system that allows for easy assembly and disassembly of battery cells without welding, enabling customers to replace specific cells independently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery cells are welded to form a dense structure, then electrical connection and structural stability are improved, but ease of repair and maintenance deteriorate because individual cells cannot be replaced
Solution Approach 1:
The battery pack is divided into independent battery cell cartridges that can be individually removed and replaced. Each cartridge contains a battery cell and its associated lead jig, allowing the cell to be segmented from the overall pack structure for independent maintenance without affecting other cells.
Solution Approach 2:
The battery cell is extracted from its cartridge and replaced independently. The cartridge structure allows the cell to be taken out without removing the entire battery pack, enabling selective replacement of only the defective cell while retaining functional cells.
2Strength
If battery cells are welded together, then manufacturing strength is improved, but manufacturing precision and assembly flexibility deteriorate due to permanent bonding
Solution Approach 1:
A lead jig acts as an intermediary component between the battery cell leads and the cartridge structure. This mediator enables electrical connection and mechanical support without permanent welding, allowing for reversible assembly and disassembly while maintaining connection strength.
Solution Approach 2:
The connection system transitions from static welded bonds to dynamic, reversible connections. The lead jig can be mounted and demounted, providing adaptability in assembly and maintenance operations while maintaining structural integrity during operation.
3Reliability
If the entire battery module is replaced when a cell fails, then reliability is maintained, but loss of time and cost increase significantly
Solution Approach 1:
The battery pack is segmented into replaceable cartridges, allowing only the defective cell to be replaced rather than the entire module. This reduces replacement time and cost while maintaining system reliability through selective component replacement.
Solution Approach 2:
Only the defective battery cell is discarded and replaced, while functional cells are recovered and retained in the pack. This selective replacement approach minimizes waste and reduces the time and resources required for maintenance.
4Manufacturing precision
If battery cells are permanently assembled, then manufacturing precision is improved, but adaptability and ease of operation deteriorate
Solution Approach 1:
The assembly system incorporates dynamic, reversible connections through the lead jig that can be mounted and demounted. This provides adaptability for cell replacement while maintaining precise electrical and mechanical connections during operation.
Solution Approach 2:
The lead jig serves as a reversible intermediary that enables precise electrical connection without permanent bonding. It allows for accurate alignment and connection during assembly while permitting easy disassembly for maintenance or reconfiguration.
Data Source
AI summary
The battery pack includes a casing, at least two battery cells, and a system including a cartridge in which the battery cell is received and a lead jig, wherein the cartridge is configured to be opened and closed to attach/detach the battery cell, and the lead jig is configured to be mounted/demounted on/from a lead of the battery cell, and when the battery cell is received in the cartridge and stacked in a thickness direction and the lead jig is mounted on the lead of the battery cell, an electrical connection is established between the battery cells without welding the leads of the battery cells.