Magnetic Battery-to-Busbar Interface for Fast Isolation

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Solution Overview

Problem

The assembly of metal-ion battery packs with electrical connection bars is time-consuming and costly, and existing solutions for disconnecting faulty accumulators within the pack are complex and not fully effective in preventing thermal propagation and ensuring safety.

Innovation Solution

A connection/disconnection device using a magnetic lock system with permanent magnets and ferromagnetic parts, allowing for easy assembly and disassembly of accumulators from busbars, and incorporating a mechanism for thermal runaway protection to prevent fault propagation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional mechanical connection methods are used for assembling accumulators to busbars, then the connection is reliable, but the assembly time and cost increase significantly

Engineering Contradiction:

Improveconnection reliabilityVSAvoidassembly speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces conventional mechanical fastening systems (screws, clips, or welding) with a magnetic connection system. The magnetic connector includes permanent magnets that create strong magnetic fields to hold the accumulator to the busbar, enabling tool-free attachment and detachment while maintaining reliable electrical and mechanical connection during operation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If conventional mechanical fastening systems are used, then the connection is secure, but the disconnection process becomes time-consuming and complex

Engineering Contradiction:

Improveconnection strengthVSAvoiddisassembly time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The magnetic connector uses magnetic attraction forces to provide secure holding strength during operation, yet allows for simple manual detachment by overcoming the magnetic force, eliminating the need for tools or complex disassembly procedures required by mechanical fastening systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The magnetic connection provides dynamic characteristics where the connection strength is sufficient to withstand vibration and mechanical stresses during operation, but can be easily released when needed, adapting between secure attachment and simple detachment states.

Inventive Principle:

Principle #15Dynamics

3Reliability

If existing disconnection mechanisms are implemented, then fault isolation is possible, but the system complexity and cost increase

Engineering Contradiction:

Improvesafety and fault isolationVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The magnetic connector integrates both connection and disconnection functions into a single simple mechanism, eliminating the need for separate mechanical fastening systems and complex electrical disconnect mechanisms, thereby reducing overall system complexity while maintaining safety and fault isolation capabilities.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

This solution reduces assembly time and costs while ensuring safe and efficient operation of battery packs by enabling quick isolation of faulty accumulators and preventing thermal runaway, thus maintaining pack integrity and safety.

Implementation Method 1

forming between them a volume in which are housed two permanent magnets distributed around the longitudinal axis (X) with their opposite magnetic poles in magnetic series and connected to each other by the first ferromagnetic part and each connected respectively to the second and third ferromagnetic part by constituting a magnetic lock

Methodology Applied

Scientific EffectMagnetism: Magnetism

Implementation Method 2

at least a fourth ferromagnetic part, integral with the busbar (B1), forming a closing plate of a magnetic circuit with the magnetic lock, the closed magnetic circuit ensuring, during normal operation of the at least one accumulator, a mechanical and electrical connection between the at least one accumulator and the busbar

Methodology Applied

Scientific EffectMagnetic circuit: Magnetic Field

Data Source

PatentEP3879050B1Interface adapter integrating a magnetic latch accommodating or formed by at least one accumulator and ensuring the magnetic fixing of the latter with electrical conduction to a busbar (B1)

Publication Date: 2024.05.22 COMMISSARIAT A LENERGIE ATOMIQUE ET AUX ENERGIES ALTERNATIVES

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AI summary

A connection/disconnection device between at least one battery (A) and a busbar (B1), comprising an interface adapter incorporating a magnetic lock housing the battery(ies) or formed by them, and ensuring the magnetic attachment of the battery(ies) with electrical conduction to the busbar. The invention relates to a device that integrates within an interface adapter a magnetic lock that fully houses the battery or is partially formed by the battery packaging itself, and that forms, with a magnetic locking plate attached to a busbar, a closed magnetic circuit, enabling mechanical and electrical connection/disconnection, by magnetic locking/unlocking, between the battery and a busbar.