Removable Battery Module With Mechanical Compression Connectors
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Solution Overview
Problem
Existing battery packs for electric vehicles face challenges such as complex and lengthy welding processes, inefficiencies due to incorrect welding, difficulty in disassembly for maintenance, and the presence of cumbersome and expensive BMS units with high electrical resistance and overheating issues.
Innovation Solution
A battery module design featuring removable support bodies with conductive elements and elastomeric materials for secure electrical connections, integrated temperature sensors, and simplified BMS components, allowing easy disassembly and assembly without welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to connect connection bars to cell terminals, then electrical connection reliability is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent replaces the welding process (thermal/chemical system) with a mechanical compression system. Connection bars with elastic elements apply continuous mechanical pressure to contact cell terminals, establishing electrical connection through conductive contact rather than metallurgical bonding. This eliminates welding complexity while maintaining connection reliability through sustained contact force.
2Reliability
If welding is used to connect connection bars to cell terminals, then electrical connection is achieved, but manufacturing time increases
Solution Approach 1:
The mechanical compression connection system eliminates the time-consuming welding process. Connection bars with elastic elements can be quickly positioned and compressed against cell terminals, establishing electrical connection instantaneously without heating, cooling, or post-weld inspection cycles required by traditional welding methods.
3Productivity
If incorrect welding is performed, then assembly speed may be maintained, but battery efficiency and life are reduced
Solution Approach 1:
The mechanical compression system eliminates welding quality issues entirely. The elastic elements automatically apply consistent, controlled force to ensure optimal contact pressure between connection bars and cell terminals. This eliminates problems such as insufficient weld penetration, excessive heat input, or contamination that can occur with welding, while maintaining high assembly speed through simple compression action.
4Reliability
If copper thin plates are used for contact portions, then electrical conductivity is improved, but contact force is reduced due to low yield point
Solution Approach 1:
The connection bar employs a composite structure combining copper (for electrical conductivity) with elastic elements providing mechanical strength. The copper portion ensures low electrical resistance at contact interfaces, while the elastic elements (made of high-strength materials) provide sustained contact force. This composite approach resolves the contradiction between conductivity and strength that plagues pure copper thin plates.
5Strength
If steel elastic elements are used for contact portions, then contact force is maintained, but electrical resistance increases causing overheating
Solution Approach 1:
The composite connection bar structure separates the functions of force application and electrical conduction. Steel or other high-strength elastic elements provide the necessary contact force, while copper sections provide low-resistance electrical pathways. This functional separation eliminates the overheating problem associated with using steel elastic elements that have high electrical resistance.
6Reliability
If BMS units include voltage sensors, temperature sensors, and microcontrollers, then battery control and management functions are achieved, but device complexity and cost increase
Solution Approach 1:
The patent integrates BMS functionality directly into the connection bar structure. Temperature sensors are embedded within the connection bar to monitor cell terminal temperatures, and control electronics are incorporated into the same component. This merging of BMS functions with the mechanical connection structure eliminates the need for separate, complex BMS units, reducing overall system complexity while maintaining full monitoring and control capabilities.
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
Facilitates quick and efficient maintenance, reduces overheating and resistance, and minimizes BMS complexity and cost by enabling non-destructive disassembly and reassembly of battery modules.
Implementation Method 1
an elastic element made of an elastomeric material arranged to resiliently push the conductive element towards the terminal in such a way to guarantee the electrical connection
Data Source
Figure 1A~1B
Figure 2
Figure 3A~3B
AI summary
A battery module (1) comprising a plurality of cells (10) arranged according to at least one row (15), each cell (10) of said plurality having a positive terminal (11) and a negative terminal (12) positioned at opposite ends. A first and a second connection bar (31, 32), or busbar, are, furthermore, provided electrically connected to the positive terminals (11) and to the negative terminals (12) of the cells (10). Support bodies (21a-21d) are, furthermore, provided with respective conductive elements (41) which comprise a respective connection portion (45) and a plurality of contact portions (43). An engagement group (51-57) is, furthermore, provided that removably mechanically engage the support bodies (21a-21d) in a predetermined working position, in which the connection portions (45) are mechanically forced to be arranged in contact with the first, or the second, connection bar (31,32), and each contact portion (43) to be arranged in contact, with a respective positive terminal (11) or with a respective negative terminal (12) of the cells (10), in such a way to make the electrical connection between the first and the second connection bar (31, 32) and the plurality of cells (10) [Fig. 1].