Modular Battery Pack Assembly for Thermal and Structural Fit
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Solution Overview
Problem
Existing battery solutions for industrial and mobile applications lack mechanical strength, reliability, and adaptability to meet power, thermal management, and volume requirements, necessitating costly redesigns and are not suitable for low-volume manufacturing.
Innovation Solution
A modular battery pack design with adjustable battery module configurations, thermal management, and electrical connections, allowing easy adaptation to various power, thermal, and structural requirements, and compatibility with existing vehicle designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If off-the-shelf battery solutions are used, then cost is reduced, but mechanical strength and reliability are insufficient
Solution Approach 1:
The battery pack is divided into modular battery modules that can be independently configured. Each module contains battery cells with integrated thermal management channels, allowing the system to achieve required mechanical strength through modular assembly while maintaining cost-effectiveness through standardized components.
Solution Approach 2:
The battery module housing combines structural support functions with thermal management functions through integrated coolant channels. This composite structure provides both the mechanical strength required for industrial applications and the thermal management capability, eliminating the need for separate structural components.
2Reliability
If custom-engineered battery packs are developed, then mechanical strength and reliability are improved, but manufacturing cost increases
Solution Approach 1:
The battery module housing serves multiple functions simultaneously: structural support, thermal management through integrated coolant channels, and electrical insulation. This multi-functionality allows custom-engineered reliability without the full cost of completely custom-designed components, as the same modular housing design can be standardized across different applications.
Solution Approach 2:
By segmenting the battery pack into standardized modules with integrated functions, the system achieves custom-engineered performance through configuration rather than complete customization, reducing manufacturing costs while maintaining reliability.
3Adaptability or versatility
If battery module configuration is adjusted, then adaptability to various requirements is improved, but device complexity increases
Solution Approach 1:
The battery pack is segmented into identical or similar modular units that can be configured in different arrangements (series/parallel connections, different physical layouts) to meet various power and thermal requirements. This segmentation enables adaptability through simple reconfiguration rather than redesign, managing complexity while maintaining versatility.
Solution Approach 2:
The modular configuration allows dynamic adaptation to different applications by changing the number and arrangement of modules without changing the fundamental module design. This enables the system to adapt to various power, thermal, and volume requirements while keeping the base module design simple and standardized.
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
The design provides a flexible and reliable electrical power solution that meets diverse mechanical and thermal needs, facilitating easy integration into a range of machinery without significant redesign, reducing costs for low-volume manufacturers.
Implementation Method 1
a battery pack fluid connection means for connecting the battery pack to a source of thermal management fluid
Implementation Method 2
a battery module comprising one or more cells and a thermal management means for thermally managing the one or more cells
Data Source
AI summary
A battery pack comprising: one or more battery modules and a battery module sub assembly; a battery pack management arrangement for monitoring and/or controlling the operation of the battery pack; a battery pack fluid connection assembly for connecting one or more ducts of the battery pack to a source of thermal management fluid; and a battery pack electrical connection arrangement for electrically connecting the battery pack to an external load, the battery pack being modular so as to be adaptable to suit multiple design requirements by adjusting the size, number, location and/or orientation of one or more battery modules within the battery pack.