Battery Backplane With Sliding Bus Bar for Hot-Swappable Modules
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Solution Overview
Problem
Existing battery assembly architectures lack flexibility and are not hot-swappable, leading to inefficient maintenance and higher costs due to the need to replace entire modules when individual components malfunction or degrade.
Innovation Solution
The implementation of a backplane with movable bus bars and socket blocks that allow for individual components to be hot-swapped, along with a cooling mechanism to regulate temperature and control electrical topology, enabling flexible and efficient balancing of battery components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional battery module architecture is used, then structural simplicity is maintained, but maintenance flexibility and hot-swappability are lost
Solution Approach 1:
The battery assembly is divided into independent replaceable modules that can be individually removed and replaced without affecting other modules. Each module contains complete functional units (cells, bus bars, cooling channels, housing) that can be independently serviced, enabling hot-swappability and maintenance flexibility while managing system complexity through modular design.
2Reliability
If entire battery modules are replaced when individual components malfunction, then reliability is maintained, but resource waste and maintenance costs increase
Solution Approach 1:
The malfunctioning component (individual cell or sub-module) is extracted and removed from the battery assembly while the remaining functional modules continue to operate. The backplane architecture enables selective removal of only the defective unit, allowing healthy cells to remain in service and be reused, thereby reducing resource waste and maintenance costs while maintaining system reliability.
3Adaptability or versatility
If fixed electrical topology is used, then structural simplicity is maintained, but adaptability for different operational modes is limited
Solution Approach 1:
The electrical topology of the battery assembly is made dynamic through movable bus bars that can be repositioned to change connection configurations. This allows the system to adapt between different operational modes (e.g., series/parallel configurations, different module arrangements) without requiring complete system disassembly, providing topology adaptability while using a relatively simple mechanical adjustment mechanism.
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 easy and cost-effective maintenance by allowing individual components to be replaced without disrupting the entire system, reducing waste and maintenance costs while maintaining system efficiency.
Implementation Method 1
a sliding bus bar configured to be movable between a first position with respect to the plurality of socket blocks and a second position with respect to the plurality of socket blocks
Implementation Method 2
The plurality of coolant pipes are configured to thermally couple to corresponding coolant pipes in one or more of the plurality of battery components
Data Source
AI summary
A battery assembly can include a backplane comprising a plurality of socket blocks configured to electrically couple respectively to a plurality of battery components. The socket blocks may provide a flexible connection between the battery components and the backplane that allows individual battery components to be replaced without removing entire modules from service. Additionally, the backplane may include a sliding bus bar that controls the electrical connection topology between the socket blocks as it is moved between a first position and a second position with respect to the socket blocks. The backplane may also be configured to connect to a cooling system for the battery components so that the temperature of the battery components can be regulated.