Composite Battery Mounting with Replaceable Cells and Fuse Protection
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Solution Overview
Problem
Existing composite batteries and battery packs lack user-friendly and cost-effective solutions for replacing defective cells, leading to premature disposal and environmental concerns, as well as limitations in configuring voltage, power, and shape for specific applications.
Innovation Solution
A mounting device with a circuit board and housing that allows for secure, detachable connection of battery cells, featuring electrical contacts, switch elements, and safety devices like overcurrent fuses, enabling users to configure and replace cells easily, ensuring safe and efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery cells are firmly connected by spot welding in pre-assembled composite batteries, then operational reliability is improved, but repairability deteriorates as defective cells cannot be replaced
Solution Approach 1:
The patent divides the battery system into modular components where individual battery cells can be independently accessed and replaced. The housing is designed with removable sections that allow users to extract and insert cells without disassembling the entire battery pack, enabling simple repair of defective cells while maintaining the integrity of the overall system.
Solution Approach 2:
The patent introduces spring-loaded contact elements as intermediaries between the battery cells and the circuit board. These elastic contacts provide reliable electrical connection through mechanical pressure rather than permanent welding, allowing cells to be easily removed and reconnected without specialized tools or equipment.
2Stability of the object's composition
If battery cells are encapsulated in a plastic matrix, then structural stability is improved, but repairability deteriorates as cell replacement becomes impossible
Solution Approach 1:
The patent segments the housing into removable parts that enclose the battery cells during operation but can be easily separated when repair is needed. This allows the structural stability benefits of encapsulation to be maintained during normal use while enabling cell replacement when defects occur.
Solution Approach 2:
The patent transitions from a static, permanent encapsulation structure to a dynamic system where the housing can change state between enclosed (for stability) and open (for repair). The removable housing sections allow the system to adapt between these two states as needed.
3Reliability
If electronic protection circuits are used to monitor compound battery function, then safety is improved, but cost increases due to inability to reuse intact cells after one cell failure
Solution Approach 1:
The patent implements protection circuits that monitor individual cells separately rather than treating the battery as a single unit. This granular monitoring approach, combined with modular cell replacement capability, allows the system to detect and isolate failures while enabling users to replace only the defective cell and continue using the remaining functional cells, reducing overall costs.
Solution Approach 2:
The patent enables recovery and reuse of functional battery cells after a failure event. By allowing individual cell replacement rather than requiring disposal of the entire battery pack, the system recovers value from intact cells that would otherwise be discarded, reducing waste and cost.
4Power
If standardized battery cells are connected in series for high voltage, then power output is improved, but safety deteriorates due to inability to replace defective cells without specialized equipment
Solution Approach 1:
The patent designs the housing and electrical connections so that individual cells in series configurations can be independently accessed and replaced. The spring-loaded contacts and removable housing sections allow users to work on single cells without needing to discharge or disassemble the entire high-voltage battery pack, making series configurations user-friendly despite the high power involved.
Solution Approach 2:
The spring-loaded contact elements serve as intermediaries that maintain reliable electrical connection in high-voltage series configurations while allowing easy cell replacement. These elastic contacts provide mechanical pressure for stable connection without requiring welding or specialized tools, enabling users to safely service high-power battery systems.
Data Source
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Figure 3~4(b)
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AI summary
The invention relates to an assembly device (1) for a compound battery (7) consisting of several battery cells (71), comprising a circuit board (2) with electrical conductors and switching elements for connecting the battery cells in parallel or series, a safety device with fuses (51) for overcurrent protection of each battery cell, a housing with two housing parts (61, 62) having contact areas (63) for fixing the battery cells, wherein the contact areas of at least one housing part are designed as recesses (64) for enclosing a battery cell, the circuit board comprises recesses (23) for receiving and contacting (31, 32) each of a battery cell in each recess, and wherein each recess encloses a recess with a battery cell in its maximum cross-sectional area.The assembly device enables a user to safely, easily and cost-effectively provide a compound battery with replaceable battery cells of different design, power and operating voltage in series or parallel connection with overcurrent protection at the cell level, as well as a battery pack (8) with appropriately configured compound batteries.