Structural Battery Module Coupling for Flexible Pack Assembly
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Solution Overview
Problem
Current battery technologies face challenges in meeting a broad range of size and performance requirements, leading to increased inventory and tooling costs, as well as difficulties in disposal and recycling due to diminished capacity or performance.
Innovation Solution
A modular battery system comprising rectangular housing with front and rear plates, featuring bores for secure coupling of modules, allowing for flexible configuration of battery packs without an external frame, using couplers through aligned bores for stability and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a plurality of battery modules are assembled into various sizes to meet different application requirements, then adaptability is improved, but device complexity increases
Solution Approach 1:
The battery system is divided into standardized modular units, each containing a battery assembly with integrated housing, terminals, and coupling features. These modules can be assembled in different configurations to create battery packs of various sizes and capacities, allowing adaptability across applications while maintaining consistent module-level simplicity
Solution Approach 2:
The battery modules are designed with universal coupling features including standardized housing bores, front plate bores, rear plate bores, and coupling bosses that enable the same module design to be used in multiple configurations and applications. The modular design allows modules to serve different functions depending on how they are assembled into battery packs
2Ease of manufacture
If standardized battery modules are used across applications, then manufacturing cost is reduced, but flexibility in meeting specific performance requirements decreases
Solution Approach 1:
The battery system uses standardized modular units that can be manufactured using consistent processes and tooling, reducing manufacturing costs. These modules are then segmented and assembled into different configurations to meet specific performance requirements, maintaining both manufacturing efficiency and application flexibility
Solution Approach 2:
The modular design allows the battery system to dynamically adapt to different performance requirements through configuration changes rather than requiring different module designs. The same standardized modules can be arranged in series or parallel configurations, or assembled in different quantities, to achieve various voltage, capacity, and power outputs
3Ease of operation
If modular design with coupling features is implemented, then assembly flexibility is improved, but structural complexity increases
Solution Approach 1:
The coupling mechanism is segmented into discrete, standardized features including housing bores, front plate bores, rear plate bores, and coupling bosses. These segmented coupling features enable flexible assembly of battery modules in different configurations while maintaining consistent, simple coupling interactions between modules
Solution Approach 2:
The coupling bosses and aligned bores serve as intermediary features that facilitate the connection between adjacent battery modules. These intermediary coupling features enable assembly flexibility by providing standardized connection points without requiring complex integrated coupling mechanisms
Data Source
AI summary
A battery module for construction of a battery pack includes a battery sealed in a rectangular housing with front and rear open ends closed by front and rear plates, respectively. The rear plate includes a plurality of rear plate bores in axial alignment with a plurality of housing bores proximal the rear open end of the housing. The front plate includes a plurality of front plate bores in axial alignment with a plurality of housing bores proximal the front open end of the housing. The front plate additionally includes positive and negative terminals electrically connected to the battery.