Battery Module Connector Layout for Rotatable Series-Parallel Assembly
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Solution Overview
Problem
Existing battery modules require elaborate components and additional design efforts to accommodate different battery sizes or electric properties, leading to increased costs and installation time, and lack modular thermal management solutions.
Innovation Solution
A battery module design with horizontally stacked cells and modular connectors allowing for easy configuration of series and parallel circuits by rotating modules, combined with a thermal management system using heat transfer fluid and a Battery Management System for signal processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If battery modules are built in horizontal or vertical configurations with fixed shapes, then structural stability is achieved, but adaptability to different battery sizes and electric properties deteriorates
Solution Approach 1:
The battery module is divided into multiple independent battery cell slots that can be individually configured. Each slot can accommodate different battery sizes and types, allowing the module to be segmented and reconfigured for different applications without changing the overall structural framework.
Solution Approach 2:
The module housing is designed with universal connector interfaces (first and second module upper/lower connectors) that can accommodate multiple battery configurations. The same housing structure serves multiple functions by supporting different battery arrangements (horizontal/vertical stacking) and electrical configurations (series/parallel) through standardized connector locations.
2Adaptability or versatility
If elaborate extra components are added to solve non-standard configurations, then configuration flexibility improves, but device complexity and cost increase
Solution Approach 1:
The connector design provides universal interfaces that work across multiple configurations. The first and second module upper connectors and corresponding lower connectors are positioned to work with various battery arrangements without requiring additional specialized components for each configuration type.
Solution Approach 2:
The electrical configuration is made dynamic through the ability to rotate battery modules 180 degrees and reposition connectors. This allows the same physical hardware to dynamically adapt between series and parallel electrical configurations without adding extra components.
3Adaptability or versatility
If completely new battery packs are developed for different battery systems, then specific functionality requirements are met, but development time and cost increase
Solution Approach 1:
A single battery module design with universal connectors and standardized housing can serve multiple battery system requirements (24V, 48V, different chemistries like NMC or LFP). The same module housing and connector design accommodates different battery cells, eliminating the need to develop completely new products for each specific functionality.
Solution Approach 2:
The battery pack is segmented into interchangeable modules that can be independently configured. This modular approach allows specific functionality to be achieved by selecting and arranging different battery cells within the same module framework, rather than developing entirely new integrated systems.
4Manufacturing precision
If battery modules use fixed connector positions, then manufacturing precision is improved, but adaptability to different electrical configurations deteriorates
Solution Approach 1:
The connector positions are asymmetrically designed with first and second module upper connectors at different locations, each with specific shapes that fit corresponding lower connectors. This asymmetric positioning enables different electrical configurations (series/parallel) while maintaining precise manufacturing locations for each connector.
Solution Approach 2:
The electrical configuration adaptability is achieved dynamically through the ability to rotate modules 180 degrees, which repositions the connectors relative to each other. The fixed connector positions maintain manufacturing precision, while the rotational capability provides dynamic reconfiguration between different electrical configurations.
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 flexible configuration of voltage and capacity without additional design efforts, reduces costs, and facilitates modular thermal management and electrical connections.
Implementation Method 1
a cooling plate configured to be in thermal contact with the battery cells, wherein the cooling plate is configured to let pass a heat transfer fluid
Data Source
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AI summary
A battery module (1) comprises battery cells (3), a module housing (2) having a upper and lower side and accommodating the battery cells (3), and a first module upper connector (4) and a second module upper connector (5) connected to the battery cells (3), a first module lower connector (6) connected to the first module upper connector (4), and a second module lower connector (7) connected to the second module upper connector (5). A first module upper connector location horizontally corresponds to a first module lower connector location and a second module upper connector location horizontally correspond to a second module lower connector location. The first module upper connector (4) fits to the first (6) and second (7) module lower connector to create contact, and the second module upper connector (5) fits to the second module lower connector (7) to create contact.