Battery Module Frame Structure for Scalable Cell Stack Replacement

Solution Overview

Problem

Existing battery packs and modules face challenges in achieving a cost-effective, space-efficient, and reliable configuration that allows for easy scalability and modular replacement of cell stacks.

Innovation Solution

A battery module design featuring longitudinal and crossbeam frame members forming receiving spaces for separate cell stacks, with holders that facilitate easy insertion and removal, and a cooling plate member for efficient cooling, along with identical frame members for cost-effective construction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If battery cells are arranged in a fixed integrated structure, then structural integrity is improved, but scalability and ease of replacement are worsened

Engineering Contradiction:

Improvestructural integrityVSAvoidscalability

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The battery module is divided into multiple separate cell stacks (first cell stack, second cell stack, third cell stack) that are arranged side-by-side within a common holder. Each cell stack can be independently installed, removed, or replaced while maintaining the overall structural integrity of the battery module through the frame structure and holder design.

Inventive Principle:

Principle #1Segmentation

2Strength

If battery cells are arranged in a fixed integrated structure, then structural integrity is improved, but ease of replacement is worsened

Engineering Contradiction:

Improvestructural integrityVSAvoidease of replacement

Core Design Contradiction:

StrengthVSEase of repair

Solution Approach 1:

The battery module is divided into multiple separate cell stacks (first cell stack, second cell stack, third cell stack) that are arranged side-by-side within a common holder. Each cell stack can be independently installed, removed, or replaced while maintaining the overall structural integrity of the battery module through the frame structure and holder design.

Inventive Principle:

Principle #1Segmentation

3Volume of moving object

If multiple cell stacks are arranged side-by-side, then space efficiency is improved, but structural complexity is worsened

Engineering Contradiction:

Improvespace efficiencyVSAvoidstructural complexity

Core Design Contradiction:

Volume of moving objectVSDevice complexity

Solution Approach 1:

Multiple cell stacks (first, second, and third cell stacks) are arranged side-by-side within a single common holder that integrates support, protection, and alignment functions. The holder is secured to the frame structure, combining multiple structural elements into a unified assembly that reduces overall complexity compared to separate mounting structures for each cell stack.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20250210782A1Battery module, a battery pack, and a vehicle

Publication Date: 2025.06.26 VOLVO TRUCK CORP

AI summary

A battery module for a battery pack has a first and a second longitudinal frame member extending in the longitudinal direction. At least three crossbeam frame members extend in the width direction. At least two separate cell stacks, each has a set of cylindrical battery cells and a holder in which the set of cylindrical battery cells are received.