Reversible Battery Pack Frame for Removable Cylindrical Cells
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Solution Overview
Problem
Large format lithium-ion battery packs assembled with cylindrical cells using permanent techniques are difficult to repair, reuse, and recycle, posing challenges for waste management and resource efficiency.
Innovation Solution
A battery pack assembly design featuring two holding frames that reversibly secure cells with a fastening mechanism, allowing for complete disassembly, and incorporating elastomeric protrusions and conductive means for efficient electrical connection and disconnection, enabling easy access and replacement of cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If permanent assembly techniques (structural adhesives, soldering) are used to connect cells in a battery module, then the structural strength and electrical connection reliability are improved, but the ease of repair, reuse, and recycling deteriorates
Solution Approach 1:
The battery module is segmented into discrete, independently removable cells held within a frame structure. Each cell can be individually accessed and removed by simply opening the frame, eliminating the need for destructive disassembly of permanent connections. This segmentation enables easy repair, reuse, and recycling while maintaining reliable electrical connections through reversible fastening mechanisms.
2Stability of the object's composition
If permanent assembly techniques are used to assemble battery modules, then the structural stability is improved, but the adaptability for repurposing and recycling deteriorates
Solution Approach 1:
The battery module employs dynamic, reversible fastening mechanisms instead of permanent static connections. The frame structure allows cells to be easily inserted and removed, enabling the module to be reconfigured, repurposed, or recycled. This dynamic approach maintains structural stability during operation while providing adaptability for future uses, directly addressing EU waste management legislation requirements.
3Strength
If cells are tightly secured in a closed assembly, then the structural integrity and safety are improved, but the ease of access for maintenance and replacement deteriorates
Solution Approach 1:
The closed assembly is designed as a segmented frame structure with removable components rather than a monolithic sealed unit. This allows the assembly to maintain structural integrity and safety when closed, while enabling easy access to individual cells by simply opening the frame. The segmented design resolves the contradiction between security and accessibility.
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 repair, reuse, and recycling of individual components, aligning with EU waste management regulations, reducing costs and resource consumption, while allowing for flexible rebuilding and repurposing of battery modules.
Implementation Method 1
at least one holding frame comprising one or more elastomeric protrusions and wherein the conductor is positioned such that at least a part of the conductor lies between one or more elastomeric protrusions and one or more cell terminals, such that with the frames in the closed condition the conductor is urged into contact by the elastomeric protrusions with said one or more terminals
Data Source
AI summary
A battery pack assembly (1) comprising two holding frames (3), wherein the two holding frames (3) hold a plurality of cells (2) between them, each cell (2) being held longitudinally between the two holding frames (3), wherein two or more of the plurality of cells (2) are connected by a conductive means (7), and wherein the two holding frames (3) are reversibly held together by a fastening means (10), wherein the fastening means (10) cause terminals of the cells (2) to be urged against the conductive means (7) and removal or loosening of the fastening means (10) enables the cells (2) to be freed from the assembly (1), at least one holding frame (3) comprising one or more elastomeric protrusions (6) and wherein the conductive means (7) are positioned such that parts of them lie between one or more elastomeric protrusions (6) and one or more cell terminals, such that the urging of the frames (3) together by the fastening means (10) causes the conductive means (7) to be urged into contact by the elastomeric protrusions (6) with said one or more terminals.