Modular Battery Rack With Releasable Fastening Elements
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Solution Overview
Problem
Existing secondary battery manufacturing methods do not allow for easy replacement of electrochemical cells, limiting the lifetime and versatility of secondary batteries, which are crucial for energy storage in mobile applications and grid systems.
Innovation Solution
A battery rack with releasable fastening elements and electrical contact elements that enable the reversible attachment and detachment of pouches containing electrochemical cells, allowing for easy replacement and modular configuration of the battery system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If electrochemical cells are permanently fixed in the battery using conventional manufacturing methods, then assembly speed and initial productivity are improved, but the battery cannot be serviced or have cells replaced, limiting its lifetime
Solution Approach 1:
The battery is divided into modular pouches, each containing one or more electrochemical cells. Each pouch can be independently removed and replaced via the releasable fastening elements, allowing selective replacement of defective or aged cells without replacing the entire battery, thus extending battery lifetime while maintaining assembly simplicity
Solution Approach 2:
The fastening elements transition from a fixed permanent state to a dynamic releasable state, enabling the battery structure to adapt between assembly mode (quick attachment) and service mode (easy replacement). This dynamic capability allows the same structure to serve both manufacturing efficiency and serviceability requirements
2Adaptability or versatility
If electrochemical cells are permanently attached to the battery structure, then structural stability and electrical connection reliability are improved, but adaptability to different applications and serviceability are reduced
Solution Approach 1:
The releasable fastening elements serve multiple functions: providing structural support during operation, enabling quick replacement during service, and allowing reconfiguration for different applications. The electrical contact elements similarly provide both stable electrical connection and ease of disconnection, making the battery system universally adaptable while maintaining reliability
Solution Approach 2:
The releasable fastening elements act as intermediaries between the pouches and the battery structure, providing a controlled interface that ensures reliable electrical and mechanical connection during operation while enabling easy separation when needed. This intermediary mechanism reconciles the conflicting requirements of stability and adaptability
3Ease of repair
If conventional battery manufacturing methods are used, then initial production cost is reduced, but replacement of defective or aged cells is not possible, limiting serviceability
Solution Approach 1:
By segmenting the battery into replaceable pouches with releasable fastening elements, the system enables easy replacement of individual defective or aged cells. The modular design allows technicians to access and replace specific pouches without disassembling the entire battery, significantly improving ease of repair while adding only minimal structural complexity
Solution Approach 2:
The design enables discarding of defective or aged pouches and recovering of the reusable battery structure, electronics, and functional pouches. The releasable fastening elements facilitate this discarding and recovering process, allowing economical replacement of only the necessary components rather than the entire battery system
Data Source
Figure 1~2
Figure 3a~3c
AI summary
The present disclosure relates to a method for manufacturing and to a method for replacing pouches of a secondary battery. The present invention also relates to a rack or base for a secondary battery. The base comprises a plurality of reception portions wherein each one of the plurality of reception portions comprises a fastening element for receiving and mechanically supporting at least one of a plurality of pouches. A pair of electrical contact elements is provided for contacting the electrochemical cell in the pouch.