Modular Battery Pack Corner Coupling for Flexible Assembly
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Solution Overview
Problem
Current battery packs lack flexibility in configuration, making it difficult to adapt to various spatial constraints and customer needs, with limited ability to change the number of battery modules or processing units and fixed forms of appearance, which hampers productivity and assemblability.
Innovation Solution
A battery pack design that includes modular components such as battery modules and processing units with corner covers and coupling members, allowing for flexible configuration and connection of modules and units, enabling various forms and improving assemblability through commonization of parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If battery packs use fixed configuration designs, then manufacturing and assembly are simpler, but adaptability to different spatial constraints and customer needs deteriorates
Solution Approach 1:
The battery pack is divided into multiple battery modules, each with standardized corner structures. These modules can be independently configured and assembled in different arrangements to meet various spatial requirements while maintaining manufacturing simplicity through standardization.
Solution Approach 2:
The corner covers and coupling members are designed as universal components that can be applied to all battery modules regardless of their position or orientation. This allows the same standardized parts to serve multiple functions in different configurations, achieving both adaptability and manufacturing efficiency.
2Adaptability or versatility
If battery packs use modular designs with coupling members, then configurability and adaptability improve, but device complexity increases
Solution Approach 1:
The corner cover and coupling member functions are merged into a single integrated component. This coupling member simultaneously provides corner protection and enables mechanical/electrical connection between modules, reducing the total number of parts while maintaining full configurability.
Solution Approach 2:
The coupling member is designed as a universal component that performs multiple functions: structural connection, electrical connection, and corner protection. This multi-functionality reduces component variety and simplifies the overall system while enabling flexible configurations.
3Reliability
If corner covers are used to protect battery modules, then reliability and protection improve, but device complexity increases
Solution Approach 1:
The protective corner cover is merged with the coupling member into a single integrated component. This provides corner protection without requiring separate protective parts, maintaining reliability while reducing overall device complexity.
Solution Approach 2:
The corner cover is designed as a universal protective component that can be applied to all battery module corners regardless of position. This standardized approach improves reliability through consistent protection while simplifying the bill of materials.
Data Source
AI summary
A battery pack includes a first battery module having a first corner formed by two side plates; a processing unit having a second corner formed by two side plates, electrically connected to the first battery module and controlling charge/discharge of the battery module; and a first coupling member having one side fastened to the first corner and the other side fastened to the second corner.