Terminal Rail Connector for Battery Stack Cell Removal
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Solution Overview
Problem
Conventional battery pack assemblies make it difficult and time-consuming to remove and replace individual battery cells due to complex configurations, often requiring the replacement of the entire battery stack or pack.
Innovation Solution
A battery pack assembly with a battery stack case and rails that use L-shaped terminals and terminal connectors for frictional engagement, allowing for easy removal and replacement of battery cells by lifting them in and out of the stack case, along with a removable lid for access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional battery pack assemblies use complex configurations for battery cell retention and electrical connection, then reliability of electrical connection is improved, but ease of operation for removing and replacing battery cells deteriorates
Solution Approach 1:
The battery pack assembly is segmented into modular components: individual battery cells can be independently removed and replaced. The retainer assembly is separated from the battery stack case, allowing the retainer to be independently manipulated. This segmentation enables easy replacement of single battery cells without affecting the entire battery pack, resolving the contradiction between reliable electrical connection and ease of operation.
Solution Approach 2:
The retainer assembly acts as an intermediary component between the battery cell and the battery stack case. It provides a simplified interface for electrical connection and mechanical retention, allowing battery cells to be securely connected while enabling easy removal through simple lifting motion. This intermediary mechanism resolves the contradiction by mediating between reliable connection and ease of replacement.
2Reliability
If conventional battery pack assemblies require replacement of entire battery stack or pack, then reliability of system is improved, but loss of time for maintenance deteriorates
Solution Approach 1:
The battery pack assembly is designed with segmented architecture where individual battery cells are independently retainable and replaceable. The retainer assembly for each battery cell can be independently opened by lifting the battery cell upward, allowing replacement of single faulty cells without replacing the entire battery stack. This segmentation principle directly reduces maintenance time while maintaining system reliability through selective replacement.
Solution Approach 2:
The retainer assembly is pre-configured with terminal connectors and retention structures that automatically engage with battery cell terminals when the cell is placed in position. This preliminary configuration of retention and electrical connection mechanisms eliminates the need for complex assembly operations during maintenance, allowing quick replacement of individual cells without time-consuming reconnection procedures.
3Ease of operation
If battery terminals use frictional engagement with terminal connectors, then ease of operation for insertion and removal is improved, but manufacturing precision requirements worsen
Solution Approach 1:
The terminal connector features an asymmetric clip structure with a opening direction that allows easy insertion of the battery cell terminal in one direction, while providing secure retention in the opposite direction. The clip can be opened by applying force in the opening direction, allowing simple removal. This asymmetric design provides ease of operation while tolerating variations in manufacturing precision through the forgiving insertion geometry.
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
Enables quick and efficient replacement of individual battery cells, reducing time and effort compared to conventional methods, while maintaining electrical connections through the bus bar module.
Implementation Method 1
two terminals shaped such that each of the two terminals frictionally engages a corresponding terminal connector
Data Source
AI summary
A battery pack assembly made up of a battery stack case housing a plurality of battery cells abutting each other is provided for powering a vehicle, such as an electric/hybrid vehicle, and/or a vehicle's electrical components. Each battery cell may be oriented such that their respective terminals alternate in polarity. The respective terminals of each battery cell may be shaped that the terminals frictionally engage a corresponding terminal connector on either side of the battery stack case, and disengage from a corresponding terminal easily. This allows individual battery cells to be replaced/removed without having to remove the entire battery stack.