Foldable Battery Interconnection Assembly for Modular Disconnection
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Solution Overview
Problem
Existing electrical connections between battery modules are non-modular, requiring destruction for disassembly, which can damage modules and increase transport volume and risk of connector damage.
Innovation Solution
An interconnection system with a flexible connecting piece that allows modular connection and disconnection of battery components using a folding mechanism, enabling easy assembly and disassembly without damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a connecting piece is welded to battery modules for electrical connection, then electrical connectivity is achieved, but disassembly requires destruction of the connecting piece which reduces modularity and may damage modules
Solution Approach 1:
The connecting piece is divided into two separate parts: a first part attached to the first battery module and a second part attached to the second battery module. These parts can be independently assembled and disassembled, enabling modular reconfiguration without destruction. The segmentation allows the system to maintain electrical connectivity while providing flexibility for assembly and disassembly operations.
Solution Approach 2:
The connecting piece acts as an intermediary element between battery modules, providing a reversible mechanical and electrical connection. Instead of directly welding modules together, the connecting piece mediates the connection, allowing for controlled assembly and disassembly while maintaining reliable electrical contact throughout the battery system.
2Ease of operation
If the connecting piece protrudes from the battery module during transport, then assembly is enabled, but transport volume increases and the connector is at risk of damage
Solution Approach 1:
The connecting piece is designed to be nested within or alongside the battery module structure during transport. The first part can be positioned within the housing or mounting structure of the first battery module, reducing the overall transport volume. This nesting approach allows the connecting piece to be readily accessible for assembly while minimizing the space it occupies during transportation.
3Strength
If the connecting piece is rigid for structural stability, then mechanical strength is achieved, but flexibility for easy assembly and disassembly is reduced
Solution Approach 1:
Dividing the connecting piece into separate parts allows each segment to be optimized independently. The first part can be designed with features for stable attachment to the first battery module, while the second part can be optimized for attachment to the second module. This segmentation enables easier handling and assembly compared to a single rigid piece spanning both modules.
Solution Approach 2:
The connecting piece incorporates dynamic characteristics through its two-part design, allowing flexibility in the assembly process. The separate parts can be independently positioned and attached, providing operational flexibility during assembly and disassembly while maintaining mechanical strength through proper attachment mechanisms at each connection point.
Data Source
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AI summary
The interconnection assembly (10, 100, 200) comprises a first component (12), which is an electrochemical cell (18) or a battery module comprising at least one electrochemical cell (18), a second component (14), and a first connecting piece (16) comprising a first fastening portion (30) connected to an electrical connection terminal (28) of the first component (12) and a second fastening portion (32) connected by a linking portion (34). The linking portion (34) is more flexible than the first fastening portion (30) and the second fastening portion (32) in bending, the first fastening portion (30) being movable relative to the first module (12) between a folded position and an unfolded position by folding, or conversely unfolding, the linking portion (34).