Battery Module Coupling and Grounding for Cable-Managed Pack Assembly
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Solution Overview
Problem
Current battery technologies face challenges in accommodating a broad range of sizes and performance requirements, leading to increased inventory and tooling costs, as well as difficulties in disposal and recycling, and they struggle with the organization and maintenance of numerous cables and connections.
Innovation Solution
A modular battery system comprising rectangular housing with front and rear plates, featuring bores for couplers and inactive openings for cable management, allowing for flexible configuration and connection of battery modules without an external frame, and utilizing couplers and non-conductive attachments for stability and cable organization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple battery modules are assembled to meet various capacity requirements, then battery pack versatility is improved, but device complexity and cable management difficulty increase
Solution Approach 1:
The battery module housing incorporates multiple types of openings (first openings for cable passage, second openings for coupler reception, third openings for grounding) that serve different functions simultaneously. This multi-functional design allows a single standardized housing structure to accommodate various cable management, mechanical coupling, and grounding requirements across different battery pack configurations, reducing the need for specialized components for each application.
Solution Approach 2:
The housing is segmented with distinct openings for different functions: cable passages separate from coupler openings, which are separate from grounding openings. This segmentation allows independent access and management of cables, mechanical connections, and grounding paths without interference, simplifying assembly and maintenance while supporting modular battery pack configurations.
2Ease of manufacture
If standardized battery modules are used across applications, then manufacturing costs are reduced, but adaptability to different power and voltage requirements is limited
Solution Approach 1:
The battery pack system enables dynamic configuration by allowing multiple standardized modules to be assembled in different arrangements. The standardized housing with universal openings maintains manufacturing simplicity, while the flexible assembly approach allows adaptation to various power and voltage requirements through different module combinations and configurations.
Solution Approach 2:
The standardized housing design with multi-functional openings serves as a universal platform that can be adapted to different applications. The same housing structure supports various cable routing options, coupling configurations, and grounding arrangements, enabling a single standardized component to meet diverse application requirements without requiring application-specific tooling.
3Ease of operation
If modular battery design is implemented, then assembly flexibility is improved, but structural stability and cable security may be compromised
Solution Approach 1:
The housing integrates multiple functions into a single unified structure: cable management features, coupler mounting points, and grounding connections are all incorporated into the same housing component. This merging ensures that structural integrity is maintained while providing flexible assembly options, as all features are coordinated within a single standardized design rather than requiring separate components.
Solution Approach 2:
The housing is pre-configured with openings and features during manufacturing that anticipate future assembly requirements. Cable passages, coupler openings, and grounding points are all built into the housing structure beforehand, ensuring proper alignment and security without requiring complex field adjustments or additional structural reinforcements during assembly.
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. At least one of the rear plate and the front plate further includes at least one inactive opening, and at least one of a grounding cable, a clipping structure adapted to receive a cable, or a supplemental, non-conductive attachment is received by the inactive opening.