Decouplable Connecting Member for Battery Module Maintenance
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Solution Overview
Problem
Existing battery modules require cumbersome disassembly and replacement of entire units when a single battery cell fails, due to the need to remove and re-weld bus bars, making individual cell exchange difficult and time-consuming.
Innovation Solution
An energy storage apparatus with decouplable connecting members and separable intermediate parts allows for easy division and exchange of energy storage devices, where the connecting members are fixed to the intermediate parts at overlapping positions to maintain structural integrity and facilitate handling of divided units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the entire battery module is disassembled to replace a single failed battery cell, then the failed cell can be replaced, but the operation becomes extremely cumbersome and time-consuming
Solution Approach 1:
The battery module is divided into multiple battery packs, where each battery pack contains a subset of battery cells. This segmentation allows only the failed battery cell or its containing battery pack to be replaced, rather than disassembling the entire module. The frame structure includes first and second frame bodies that can separately hold different battery packs, enabling independent replacement of individual packs.
Solution Approach 2:
The failed battery cell is extracted from its containing battery pack, and the entire battery pack is removed from the frame for replacement. This extraction approach simplifies the replacement process by treating the battery pack as a modular unit that can be quickly swapped out without affecting other cells. The bus bars are designed to facilitate this extraction by allowing quick disconnection of electrical connections.
2Reliability
If bus bars are welded to battery cells for electrical connection, then reliable electrical connection is achieved, but removal and re-welding of bus bars makes cell exchange extremely cumbersome
Solution Approach 1:
The electrical connection system transitions from a static welded connection to a dynamic, adjustable connection. Bus bars are designed with flexible connection methods that can be quickly attached and detached, such as clamp connections or snap-fit mechanisms. This allows the electrical connection to adapt between states of secure connection during operation and easy disconnection during maintenance, resolving the conflict between connection reliability and replacement ease.
Solution Approach 2:
Instead of permanently welding bus bars to battery cells, the design allows for non-permanent attachment methods where bus bars can be quickly removed and recovered. The bus bar structure includes features that enable rapid detachment from battery cell terminals without damage, allowing the same bus bar to be reused for the next battery cell installation, thus facilitating quick replacement operations.
3Reliability
If the entire battery module is replaced when a failure occurs, then system reliability is maintained, but the complexity and cost of maintenance increases significantly
Solution Approach 1:
The battery module is segmented into multiple independent battery packs that can be individually replaced. Each battery pack is a self-contained unit with its own structural support and electrical connections to the frame. This segmentation reduces maintenance complexity by allowing replacement of only the failed pack rather than the entire module, while still maintaining overall system reliability through quick replacement of the defective unit.
Solution Approach 2:
The frame structure and bus bar system are designed with universal features that can accommodate multiple battery packs of the same type. The frame includes standardized mounting positions and electrical connection points that work with any battery pack in the series. This universality simplifies maintenance by allowing any failed pack to be replaced with any functional pack, reducing the need for precise matching and lowering maintenance complexity.
Data Source
AI summary
In the present embodiment, an energy storage apparatus includes: a plurality of energy storage devices arranged in a first direction; a pair of end members disposed on both ends in the first direction of the plurality of energy storage devices; a connecting member that extends in the first direction and connects the pair of end members; and an intermediate member disposed between adjacent two of the energy storage devices, wherein the connecting member is decouplable at a position corresponding to the intermediate member in the first direction, and the intermediate member includes a first intermediate part and a second intermediate part that are separable in the first direction and are engaged with each other.