Modular Battery Pack Assembly for Repairable Cylindrical Cells
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Solution Overview
Problem
Large format battery packs using cylindrical cells are difficult to maintain, repair, and recycle due to permanent assembly techniques that prevent easy access to individual components.
Innovation Solution
A battery pack assembly design featuring a holding frame, an electrically conductive conductor plate, an electrical control unit, and a separator plate that allows for easy assembly and disassembly, enabling better access for maintenance and repair without requiring the disassembly of cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If permanent assembly techniques (structural adhesives, spot welding, soldering) are used to connect battery cells, then the battery module achieves strong structural integrity and reliable electrical connections, but the individual components cannot be easily accessed or removed for repair and recycling
Solution Approach 1:
The battery pack is divided into modular components (battery module, holding frame, conductor plate, separator plate) that can be independently accessed and removed. The reversible fastening system allows the holding frame to be separated from the battery module, enabling component-level repair and recycling while maintaining structural integrity during operation.
Solution Approach 2:
The fastening system transitions from a permanent static connection to a dynamic reversible connection. The holding frame can be rapidly attached and detached using reversible fasteners, allowing the system to switch between a secure assembled state for operation and a disassembled state for maintenance and recycling.
2Reliability
If permanent assembly techniques are used to connect battery cells, then the battery module achieves reliable electrical connections, but the cells and materials cannot be easily separated for recycling
Solution Approach 1:
The battery pack is segmented into distinct components (battery module, holding frame, conductor plate, separator plate) connected by reversible fasteners. This segmentation enables complete disassembly for recycling, allowing each material type to be separated and processed appropriately while ensuring reliable electrical connections during operation.
Solution Approach 2:
The reversible fastening system enables the recovery and reuse of valuable components and materials. The holding frame, conductor plate, and separator plate can be recovered and reused, while the battery cells can be individually accessed for recycling, maximizing material recovery and reducing waste.
3Quantity of substance
If a compact battery pack design is used, then the energy density is improved, but the electrical control unit becomes difficult to access for maintenance
Solution Approach 1:
The separator plate creates a physical separation between the battery module and the electrical control unit, while the reversible fastening system provides access pathways. This allows the control unit to be integrated close to the battery for compact design while remaining accessible through the removable holding frame and separator plate for maintenance.
Data Source
AI summary
A battery pack assembly (100), the assembly (100) comprises: a plurality of cells (102a, 102b), each cell (102a, 102b) having a body portion extending between a first end having a first terminal and a second end having a second terminal, a first holding frame (101a) being configured to accommodate at least the first end of one or more of the plurality of cells (102a, 102b) and a second holding frame (101b) being configured to accommodate at least the second end of one or more of the plurality of cells (102a, 102b), an electrical control unit (103) configured to control the electrical output of the battery pack assembly (100), and a separator plate (104), wherein the separator plate (104) is located between the plurality of cells (102a, 102b) and the electrical control unit (103) and is secured to the first holding frame (101a) and the second holding frame (101b).