Detachable Battery Pack Structure for Safer Handling and Module Service
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Solution Overview
Problem
Conventional battery packs are heavy and difficult to install and transport, requiring multiple workers and posing risks during installation and maintenance, with the need for entire pack replacement when only specific modules need to be replaced.
Innovation Solution
A battery pack design featuring detachable battery modules and a pack cover with a built-in battery management system, allowing for easy installation, carrying, and modular replacement, with a support unit to secure modules and facilitate efficient handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a conventional battery pack is designed with high capacity to meet energy requirements, then the energy storage capacity is improved, but the weight increases making installation and transportation difficult and dangerous
Solution Approach 1:
The battery pack is divided into multiple detachable battery modules that can be independently handled. Each module contains a portion of the total battery cells, allowing the overall energy capacity to be achieved through combination of lighter individual modules. This segmentation enables easier installation and transportation while maintaining high total capacity.
2Stability of the object's composition
If a conventional battery pack is designed as an integrated unit to ensure structural stability, then the structural integrity is improved, but the difficulty of maintenance and replacement increases when only specific modules need service
Solution Approach 1:
The battery pack structure is segmented into modular units with standardized connection interfaces. Each battery module can be independently removed and replaced while maintaining the overall structural integrity of the pack through standardized mounting mechanisms and connection protocols.
Solution Approach 2:
The battery module connections are designed to be dynamically changeable - firmly connected during operation for structural integrity, but easily detachable for maintenance. The standardized interfaces allow for quick connection and disconnection without compromising structural stability when properly assembled.
3Ease of manufacture
If a conventional battery pack uses standardized modular design to improve ease of assembly, then the ease of manufacture is improved, but the device complexity increases due to multiple connection interfaces and alignment requirements
Solution Approach 1:
A universal standardized interface design is implemented across all battery modules, allowing the same connection mechanism to serve multiple functions: mechanical attachment, electrical connection, and alignment guidance. This multi-functionality reduces the number of separate components needed while maintaining ease of assembly.
Solution Approach 2:
Multiple functions (mechanical connection, electrical contact, positioning) are merged into a single integrated connection interface. This reduces the number of separate components and steps required for assembly while maintaining standardized modular compatibility throughout the battery pack.
Data Source
AI summary
A battery pack includes a plurality of battery modules, each having at least one battery cell; and a pack cover having a battery management system (BMS) for managing the plurality of battery modules and configured to integrally cover the plurality of battery modules.