Modular Battery Cell Carrier With Mechanical Bus Bar Supports
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Solution Overview
Problem
Conventional methods for assembling battery packs using epoxy are time-consuming, require sterile conditions to prevent contamination, and pose health risks due to noxious fumes, while also making it difficult to repair damaged cells without disrupting the entire pack.
Innovation Solution
A modular battery cell carrier with a rigid backing, bus bar supports, alignment guides, and heat conductive sheets that allows for secure stacking and assembly without epoxy, enabling quick and safe construction and easy repair of battery packs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If epoxy is used to assemble battery packs, then the cells are securely fixed, but the assembly process becomes time-consuming and requires sterile conditions
Solution Approach 1:
The invention divides the battery pack into modular units with individual cell carriers that can be independently assembled and then stacked. Each carrier is a self-contained module with integrated bus bar supports and alignment features, allowing rapid assembly without epoxy while maintaining structural integrity through mechanical interlocking of stacked carriers.
2Strength
If epoxy is used to assemble battery packs, then the cells are securely fixed, but sterile conditions are required to prevent contamination
Solution Approach 1:
By segmenting the battery pack into modular carriers with mechanical fixation features (protrusions and recesses), the invention eliminates the need for epoxy, thereby removing the requirement for sterile conditions and associated contamination risks while still providing secure cell fixation.
3Strength
If epoxy is used to assemble battery packs, then the cells are securely fixed, but health risks arise due to noxious fumes
Solution Approach 1:
The invention extracts and removes the epoxy material from the assembly process entirely, replacing it with mechanical fixation methods. This eliminates the source of noxious fumes and associated health risks while maintaining secure cell fixation through the modular carrier design with interlocking features.
4Strength
If epoxy is used to assemble battery packs, then the cells are securely fixed, but repair of damaged cells becomes difficult
Solution Approach 1:
The modular carrier design with standardized protrusion-recess interfaces allows individual cell carriers to be independently removed from the stack for repair or replacement without disturbing other cells. This segmentation enables easy maintenance while maintaining secure fixation during normal operation.
Data Source
AI summary
The present disclosure is directed at a cell carrier, a stack that includes multiple cell carriers, and a method for assembling the stack. The cell carrier has a rigid backing and bus bar supports that are rigidly mounted to the rigid backing The bus bar supports have sockets positioned to receive fasteners for securing bus bars to the bus bar supports. A battery cell that has electrodes in the form of pliable tabs can be secured to the cell carrier by, for example, adhering the cell body to the rigid backing The cell tabs are secured between the bus bars and the bus bar supports when bus bars are fastened to the bus bar supports, and the rigidly mounted supports help prevent relative motion between the cell body and tabs. This helps prevent the cell tabs from ripping or tearing when the battery cell is subjected to vibrations during use.