Battery Module with Integrated BMM Carrier for Serviceable Cell Retention
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Solution Overview
Problem
Conventional battery systems face challenges in efficient mechanical integration and maintenance, particularly in electric vehicles, due to bulky and expensive high-capacity battery modules that require dismounting the entire system for replacement of defective parts, and static power control that fails to meet dynamic power demands.
Innovation Solution
A battery module design featuring a cell carrier with form-locking cell retainers that accommodate battery management modules (BMMs) within the existing cell carrier, allowing for space-saving and efficient electrical connections, and a method for assembling these modules with a BMM carrier and adapter for easy service and replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the entire battery system is dismounted for replacement of defective parts, then maintenance can be performed, but system complexity and maintenance time increase
Solution Approach 1:
The battery system is divided into modular battery modules, each containing a subset of battery cells and an integrated BMM. This segmentation allows individual modules to be independently accessed and replaced without dismounting the entire battery system, significantly reducing maintenance time and improving accessibility.
Solution Approach 2:
The BMM is extracted from the conventional separate mounting location and integrated directly within the battery module structure. This extraction allows the BMM to be automatically removed when its associated battery module is replaced, eliminating the need for separate BMM disconnection procedures and reducing overall maintenance time.
2Device complexity
If BMMs are mounted separately from battery cells, then electrical connections are simplified, but space utilization and integration efficiency decrease
Solution Approach 1:
The BMM is merged with the battery module to which it is assigned, creating an integrated unit. This merging achieves space-saving integration while maintaining simplified electrical connections through direct coupling between the BMM and its associated battery cells within the same module.
Solution Approach 2:
The BMM is nested within the battery module structure, specifically positioned to utilize the space efficiently among the battery cells. This nesting approach maximizes space utilization while keeping the BMM closely integrated with its associated battery cells for simplified electrical connections.
3Ease of repair
If battery modules are designed with integrated BMMs, then maintenance is simplified, but manufacturing complexity increases
Solution Approach 1:
The battery system is segmented into standardized modules with integrated BMMs, where each module is designed as a self-contained unit. This segmentation simplifies manufacturing by allowing modular assembly and enables easier replacement during maintenance without requiring complex reconfiguration.
Solution Approach 2:
The battery module is designed to be self-sufficient with its BMM integrated directly into the module structure. This self-service design allows the module to function independently and be replaced as a complete unit, simplifying both manufacturing processes and maintenance procedures.
Data Source
AI summary
A battery module includes: a plurality of battery cells; a cell carrier including a plurality of cell retainers, each of the cell retainers being configured to hold one of the battery cells in a form locking manner; and a battery management module (BMM) arranged within a group of the cell retainers.