Cylindrical Battery Module Layout for Easier Assembly and Repair
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Solution Overview
Problem
The existing CTP structure for cylindrical battery cells faces challenges such as a complicated assembly process, difficulty in glue potting, and limited repairability, leading to potential safety issues and waste of the entire battery pack due to single cell quality problems.
Innovation Solution
A battery module design featuring a housing with integrated side and bottom plates, a fixing bracket with positioning grooves, a serpentine cooling plate, and a cell contact system, which simplifies assembly, positions cells effectively, and includes an exhaust channel for thermal runaway safety, allowing modular repair and replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If CTP structure directly connects large number of cylindrical battery cells in series and parallel, then energy density is improved, but assembly process complexity increases
Solution Approach 1:
The patent divides the battery pack into multiple independent modules, each containing a subset of battery cells. This segmentation reduces the complexity of assembling large numbers of cells by breaking down the overall assembly process into smaller, more manageable module assembly tasks. Each module can be assembled and tested independently before being integrated into the complete battery pack.
Solution Approach 2:
The patent employs preliminary grouping of battery cells into modules with pre-configured electrical connections and thermal management integration. This preliminary action allows cells to be organized and pre-assembled into functional units before final pack integration, significantly reducing on-site assembly complexity and enabling standardized manufacturing processes.
2Strength
If whole battery pack is potted with glue, then structural integrity is improved, but manufacturing difficulty increases
Solution Approach 1:
Instead of potting the entire battery pack as a single large unit, the patent applies glue potting to individual modules or smaller sub-assemblies. This segmentation of the potting process reduces manufacturing difficulty by making the operation more manageable, improving glue distribution control, and reducing curing time, while still achieving the required structural integrity through localized bonding.
3Reliability
If entire battery pack is disassembled for single cell repair, then reliability is maintained, but repair time increases
Solution Approach 1:
The patent designs the battery pack as modular units where individual cells or small groups of cells can be accessed and replaced independently. This modular segmentation allows defective cells to be repaired or replaced by simply removing and replacing the affected module, eliminating the need to disassemble the entire battery pack and significantly reducing repair time while maintaining overall system reliability.
Solution Approach 2:
The patent enables rapid replacement of defective battery cells or modules with pre-tested replacement units. This approach allows the defective component to be discarded and replaced without extensive diagnostics or repair procedures, minimizing downtime and maintaining high reliability through quick restoration of full system capacity.
4Ease of repair
If modular battery structure is used, then ease of repair is improved, but device complexity increases
Solution Approach 1:
The patent implements modular battery modules with standardized mechanical and electrical interfaces. Each module is designed as a self-contained unit with integrated cell groups, thermal management components, and connection terminals. This segmentation enables easy replacement of individual modules while maintaining a relatively simple overall system architecture through standardization and repetition of identical module units.
Solution Approach 2:
The patent designs universal module interfaces that can accommodate different cell configurations within the same module type. The standardized connection protocols, mechanical mounting interfaces, and thermal management connections allow the same module design to serve multiple functions and be interchangeable across different positions in the battery pack, reducing the need for multiple specialized module designs.
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
Facilitates a simpler manufacturing process, improves safety through thermal management and modular repair, and reduces waste by enabling individual module replacement, enhancing overall efficiency and scalability.
Implementation Method 1
a serpentine cooling plate, in which a cooling channel is formed, is disposed between two rows of cylindrical battery cells
Implementation Method 2
a serpentine cooling plate, in which a cooling channel is formed, is disposed between two rows of cylindrical battery cells
Implementation Method 3
an exhaust channel is formed between the fixing bracket and the bottom plate, and the exhaust channel communicates with the positioning grooves
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Abattery module and a battery pack are provided. A battery module (100), includes a housing (10), comprising a bottom plate, side plates, a top plate, and end plates, wherein the top plate is fixedly connected to the bottom plate, the side plates, and the end plates sequentially to enclose and form a containing cavity; a fixing bracket (20) located in the containing cavity and mounted on the bottom plate; a battery cell stack (30), comprising cylindrical battery cells arranged in a plurality of rows, wherein a top portion of each of the cylindrical battery cells is provided with an electrode terminal; a cell contact system (CCS) component (40), disposed on a side of the battery cell stack (30) close to the top plate, and electrically connected to the electrode terminals of the cylindrical battery cells; and a serpentine cooling plate (50) disposed between two rows of cylindrical battery cells.