Expandable Battery Module With Integral Mating Bricks
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Solution Overview
Problem
Traditional battery module assembly faces challenges such as high costs due to assembly defects, quality issues in manual manufacturing, and the need for numerous fasteners and complex bus bars, which can lead to inefficiencies and increased complexity, especially in large format modules.
Innovation Solution
A battery module design utilizing small-format 'bricks' with integral mating members for manual assembly, eliminating the need for automated joining processes and incorporating an integrated lug terminal restraint to reduce fasteners, allowing for robust mechanical and electrical connections and efficient expansion in series and parallel configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional automated assembly processes are used to connect battery cells, then manufacturing precision and consistency are improved, but device complexity and cost increase due to frequent calibration and control requirements
Solution Approach 1:
The battery module is divided into discrete brick sub-modules, each with its own integral mating members. This segmentation allows each sub-module to be assembled independently with simple manual operations, avoiding the need for complex automated assembly systems while maintaining consistent quality across all modules.
Solution Approach 2:
The integral mating members are built into the brick sub-modules themselves, providing self-aligning and self-connecting capabilities. The complementary protruding and recessed features automatically guide proper alignment during manual assembly, eliminating the need for external alignment tools or complex control systems.
2Reliability
If numerous fasteners are used to connect bus bars to battery cells, then connection reliability is improved, but device complexity and assembly time increase
Solution Approach 1:
The electrical connection and mechanical restraint functions are merged into a single integral mating member structure. The bus bar connection is integrated with the restraint feature, allowing one fastener to simultaneously secure both the electrical connection and prevent cable loosening, thereby reducing the total number of fasteners needed.
Solution Approach 2:
The integral mating members serve multiple functions: they provide electrical connection, mechanical restraint, and alignment guidance. This multi-functionality reduces the need for separate components and fasteners, simplifying the overall assembly while maintaining connection reliability.
3Adaptability or versatility
If small-format battery bricks are used instead of large modules, then adaptability and packaging options are improved, but device complexity increases due to more connection interfaces
Solution Approach 1:
The battery system is segmented into standardized brick sub-modules that can be independently configured. Each brick has identical integral mating members, providing consistent connection interfaces that simplify the overall system design despite the modular segmentation, thereby reducing the complexity increase that would normally result from more connection points.
Solution Approach 2:
The integral mating members provide universal connection capabilities that work across all brick configurations. The same mating member design is used regardless of whether bricks are arranged in series, parallel, or mixed configurations, eliminating the need for different connection interfaces and reducing overall system complexity.
4Ease of manufacture
If manual assembly processes are used for battery modules, then ease of manufacture is improved, but manufacturing precision and quality consistency worsen
Solution Approach 1:
The integral mating members with complementary protruding and recessed features provide self-aligning capabilities during manual assembly. This self-service alignment mechanism ensures consistent positioning and connection quality without requiring skilled operators or complex fixtures, thereby maintaining manufacturing precision while preserving ease of manual assembly.
Data Source
AI summary
A battery module comprising sub-module components, or bricks, that facilitate efficient assembly utilizing common hand tools and provide integrated cooling features for increased battery configurability and performance.