Stackable Pouch Cell Frames for Fast Battery Pack Replacement
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Solution Overview
Problem
Conventional energy storage systems, particularly pouch cell battery packs, lack a practical and efficient method for field replacement of battery cells, requiring complex assembly processes and heavy investment in equipment, making fast engagement and disengagement difficult.
Innovation Solution
A stackable frame design that connects pouch cell battery packs to a printed circuit board assembly via a series connection, allowing for easy cell-to-system assembly without additional bolts, clamps, or bus bars, enabling straightforward field replacement of battery cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional welding or screw connections are used to connect pouch cells to PCBA, then reliable electrical connection is achieved, but field replacement of cells becomes extremely difficult or impossible
Solution Approach 1:
The battery pack is divided into modular units where individual pouch cells can be independently accessed and replaced. The frame structure segments the cell assembly into discrete replaceable modules, allowing field replacement without disassembling the entire battery pack.
Solution Approach 2:
The connection system transitions from static permanent connections (welding) to dynamic reversible connections. The frame design enables cells to be dynamically inserted and removed through spring-loaded contacts that maintain electrical connection during assembly and disassembly operations.
2Ease of repair
If screw connections with tabs and bus bars are used, then field replacement is possible, but the assembly process becomes complex requiring sorting tabs and securing multiple components
Solution Approach 1:
Multiple separate components (tabs, bus bars, screws, insulation elements) are merged into an integrated frame structure. The frame itself serves as the electrical conductor and mechanical support, eliminating the need for separate bus bars and simplifying the connection process to a single assembly operation.
Solution Approach 2:
The frame structure performs multiple functions simultaneously: it provides mechanical support, establishes electrical connections, enables field replacement, and simplifies assembly. This multi-functional design eliminates the need for separate specialized components for each function.
3Productivity
If automatic welding lines are used for cylindrical cells, then fast assembly is achieved, but field replacement of problematic cells is not possible
Solution Approach 1:
The connection system transitions from static permanent connections (welding) to dynamic reversible connections. The frame design enables cells to be dynamically inserted and removed through spring-loaded contacts that maintain electrical connection during assembly and disassembly operations.
4Ease of manufacture
If conventional battery pack designs are used, then manufacturing is simplified, but fast disengagement for field replacement cannot be achieved
Solution Approach 1:
The battery pack is divided into modular units where individual pouch cells can be independently accessed and replaced. The frame structure segments the cell assembly into discrete replaceable modules, allowing field replacement without disassembling the entire battery pack.
Data Source
AI summary
The present disclosure provides an energy storage system. For example, an energy storage system comprises a printed circuit board assembly configured to connect to a chassis of the energy storage system and a frame assembly comprising a plurality of stackable frames configured to connect to a plurality of battery cells and the printed circuit board assembly such that a series connection between the plurality of battery cells is created when the plurality of battery cells are connected to the plurality of stackable frames.