Contactless Swappable Battery Pack With Inductive Charging Isolation
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Solution Overview
Problem
Existing battery systems face challenges in large-scale power supply due to limitations in energy transportation and storage, particularly with lithium-ion batteries, which are not well-suited for non-proprietary, interchangeable, and safe use in harsh environments.
Innovation Solution
A contactless battery system utilizing magnetic induction coupling for charging, discharging, and communication, with a sealed, rugged case providing galvanic isolation and safety features, enabling safe operation in wet, dusty, or explosive environments, and allowing for secure, off-site charging and monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If lithium-ion batteries are used for large-scale power supply, then energy storage capacity is improved, but safety and suitability for harsh environments deteriorate
Solution Approach 1:
The patent replaces traditional mechanical/electrical contact-based charging systems with wireless magnetic induction charging. The battery pack uses a wireless power receiver that couples magnetically with a charging base, eliminating the need for physical plug connections. This substitution improves safety by removing exposed electrical contacts that could cause shocks or sparks in harsh environments, while maintaining full energy storage and charging capabilities.
2Productivity
If traditional contact-based charging is used, then charging efficiency is improved, but risk of conductive contact and electrical hazards increases
Solution Approach 1:
The patent replaces mechanical plug-and-contact charging with wireless magnetic induction. The charging base generates a magnetic field that induces current in the battery pack's wireless receiver, transferring power without physical electrical contact. This maintains charging efficiency through direct magnetic coupling while eliminating all conductive contact risks, including electrical shocks, sparks, and contact wear.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary medium between the charging base and battery pack. Instead of direct electrical contact, power is transmitted through the magnetic field that couples the charging base's transmitter and the battery's receiver. This intermediary enables efficient energy transfer while completely isolating the user from electrical hazards.
3Ease of operation
If batteries are designed for interchangeability, then ease of replacement is improved, but standardization constraints and design flexibility worsen
Solution Approach 1:
The patent designs the battery pack with universal features including standardized mechanical mounting interfaces, universal wireless power coupling geometry, and standardized electrical specifications (voltage, current, communication protocols). These universal design elements enable the battery pack to be interchangeably installed in multiple device types while maintaining full functionality, resolving the conflict between ease of replacement and design flexibility through deliberate standardization of key interfaces.
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 contactless battery system ensures safe, efficient, and scalable energy storage and transportation, eliminating conductive contact risks and enabling deployment in diverse environments while facilitating secure charging and monitoring.
Implementation Method 1
The wireless power transmission coupler is disposed with respect to at least one face of the sealable case to enable magnetic inductive signaling for charging, discharging, and communication with the battery unit
Data Source
AI summary
A contactless battery system includes a sealable case, a battery unit disposed within the sealable case, and at least one wireless power transmission coupler connected to the battery unit and disposed within the sealable case. The battery unit includes an arrangement of serially connected battery cells in a fixed number of banks of battery cells to deliver a set voltage and current. The wireless power transmission coupler is disposed with respect to at least one face of the sealable case to enable magnetic inductive signaling for charging, discharging, and communication with the battery unit. A battery management controller communicates bidirectionally with the contactless battery systems and with electrically powered equipment to control charging. A distribution system manages distribution of the contactless battery systems to a plurality of depots adapted to store, charge, or exchange depleted contactless battery systems under control of at least one management unit.