Detachable Battery Module Structure for Low-Cost Battery Repair

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Solution Overview

Problem

Existing battery technologies require complete replacement of the entire battery when faulty, leading to high maintenance costs and difficulty due to sealed cases.

Innovation Solution

A battery design with detachable battery modules mounted to a load-bearing bracket, allowing individual module replacement and maintenance without opening a case.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the entire battery is sealed in a large battery case, then the battery structure is complete and protected, but maintenance difficulty increases and costs rise

Engineering Contradiction:

Improvebattery structure completenessVSAvoidmaintenance difficulty

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The battery is divided into multiple independent battery modules (first battery module, second battery module, etc.) that can be individually accessed and maintained. Each module contains its own battery cells and can be independently replaced or serviced without opening the entire battery case, thus maintaining structural completeness while enabling easy maintenance.

Inventive Principle:

Principle #1Segmentation

2Reliability

If the entire battery is replaced when faulty, then reliability is restored, but maintenance costs increase

Engineering Contradiction:

Improvebattery functionalityVSAvoidmaintenance costs

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The battery system is segmented into replaceable modules, allowing only the faulty module to be replaced rather than the entire battery. This reduces material loss and maintenance costs while restoring battery functionality, as only the defective portion needs to be removed and replaced.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

When a battery module becomes faulty, only that specific module is discarded and replaced, while the remaining functional modules are retained and continued to be used. This approach recovers and reuses the majority of the battery system, significantly reducing maintenance costs compared to replacing the entire battery.

Inventive Principle:

Principle #34Discarding and recovering

3Ease of manufacture

If battery modules are fastened through compressing, then mounting is simple, but extrusion damage occurs

Engineering Contradiction:

Improvemounting simplicityVSAvoidbattery module integrity

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The battery case is segmented into a fixed portion and a movable portion that work together with a fastening mechanism. The movable portion can be shifted to engage or disengage from the fixed portion, providing simple mounting while avoiding continuous compressive force on the battery modules.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The fastening system uses a dynamic movable portion that can be shifted between engaged and disengaged positions. This dynamic mechanism replaces static compression with a controllable mechanical engagement that secures modules during operation but allows easy release when needed, preventing extrusion damage.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentEP4648193A1Battery and electrical device

Publication Date: 2025.11.12 CONTEMPORARY AMPEREX TECHNOLOGY (HONG KONG) LIMITED

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AI summary

A battery (100) and a power consuming device (200) are provided. The battery (100) includes: a load-bearing bracket (10) and a plurality of battery modules (20). The plurality of battery modules (20) are mounted to the load-bearing bracket (10). At least one battery module (20) is detachably mounted to the load-bearing bracket (10).