Modular Battery Case Sliding Mechanism for EV Maintenance
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Solution Overview
Problem
The handling and maintenance of heavy vehicle batteries in hybrid or all-electric vehicles pose safety and logistical challenges, including physically unsafe manual handling, costly mechanical equipment requirements, cumbersome maintenance processes, and prolonged recharging times due to the difficulty in removing and replacing batteries.
Innovation Solution
A modular battery case with low-friction sliding mechanisms allows for easy insertion and removal of batteries, reducing manual effort and enabling efficient maintenance and charging without disassembling the vehicle, using a housing with elongate ridges and channels that minimize sliding resistance and support the weight of batteries, along with optional cooling ducts for temperature management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If batteries are embedded within the vehicle body, then structural integration is improved, but maintenance and safety inspection accessibility deteriorate
Solution Approach 1:
The battery system is divided into modular battery cases that can be independently removed from the vehicle. Each battery case is a separate unit that can be accessed and maintained without disassembling the entire vehicle body, thus maintaining structural integration while improving maintenance accessibility.
Solution Approach 2:
Batteries are extracted from the vehicle body as removable units. The battery cases can be taken out of the vehicle for maintenance, charging, or replacement without requiring vehicle disassembly, resolving the contradiction between structural integration and maintenance accessibility.
2Reliability
If heavy mechanical equipment is used for battery installation and removal, then handling safety is improved, but device complexity and cost increase
Solution Approach 1:
The battery case incorporates a handle that provides mechanical advantage for lifting and moving the heavy battery assembly. This simple mechanical lever system reduces the need for heavy equipment while maintaining handling safety, as the handle allows individuals to control and move batteries more easily.
Solution Approach 2:
The battery case design enables individuals to perform battery installation and removal themselves using the integrated handle and sliding mechanisms, without requiring specialized mechanical equipment. The system is designed to be self-sufficient for manual handling operations.
3Ease of manufacture
If traditional battery recharging methods are used, then infrastructure cost is reduced, but recharging time increases
Solution Approach 1:
Fully charged battery cases are prepared in advance and stored in the battery case holder. When a vehicle needs power, a charged battery can be quickly swapped in without waiting for charging, enabling fast replacement and reducing the effective recharging time while using standard charging infrastructure.
Solution Approach 2:
The system allows for the discarding of discharged batteries and recovery of pre-charged batteries through rapid swapping. This enables vehicles to quickly replace depleted power sources with fresh ones, dramatically reducing recharging time while utilizing existing charging infrastructure for battery maintenance.
4Quantity of substance
If batteries are made larger to increase power capacity, then energy storage is improved, but manual handling safety deteriorates
Solution Approach 1:
The battery case handle provides mechanical leverage that counteracts the weight of large, high-capacity batteries. This allows individuals to safely handle and move batteries with substantial energy storage capacity without proportionally increasing safety risks, as the handle reduces the effective effort required.
Solution Approach 2:
The battery case itself serves as an intermediary between the heavy battery and the handler. The case provides structural support, integrated handling features, and protective enclosure, allowing safe manual handling of high-capacity batteries that would otherwise be too heavy or hazardous to move directly.
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
Facilitates safe and efficient handling, maintenance, and charging of batteries, reducing the risk of physical harm and fire hazards while improving recharging speed and reducing capital equipment costs by enabling fast battery replacement and maintenance without dissembling the vehicle.
Implementation Method 1
A battery case may include features to allow for relatively easy or fast removal or insertion. For example, a battery case may provide a benefit in that a vehicle need not be dissembled to remove or add vehicle batteries.
Data Source
AI summary
Subject matter disclosed herein relates to an apparatus for a battery system for electric vehicles and, more particularly, to removable modular batteries and a battery case to store the batteries.