Front Access Battery Tray Modular Stacking Design
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Solution Overview
Problem
Existing battery rack systems face challenges in tight spaces due to cumbersome assembly and mounting processes, particularly when dealing with lithium ion battery modules.
Innovation Solution
A scalable and configurable front access battery tray system with a base, side panels, flanges, and a retainer bracket design that allows for easy access, stacking, and secure storage of battery modules, featuring a compact footprint and modular structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional battery rack systems are used in tight spaces, then battery storage capacity is achieved, but assembly and mounting become difficult and time-consuming
Solution Approach 1:
The battery rack system is divided into modular components including individual battery trays, side panels with integrated flanges, and detachable retainer brackets. Each tray can be assembled and positioned independently, then quickly connected to adjacent trays through the flange interfaces, enabling parallel assembly and significantly reducing installation time in confined spaces
Solution Approach 2:
The retainer brackets are designed to be detachably coupled to retainer pegs, allowing for quick assembly and disassembly without permanent fastening. This dynamic connection system enables rapid configuration changes and simplifies maintenance operations while maintaining secure battery retention during operation
2Reliability
If battery trays are designed for secure storage, then battery stability is improved, but accessibility and assembly ease are reduced
Solution Approach 1:
The design inverts the traditional approach by providing front access to battery modules rather than rear access. The open front design of the battery trays allows direct insertion and removal of batteries from the front, eliminating the need to reach around or disconnect components at the rear, thereby improving accessibility while maintaining secure retention through the retainer bracket system
Solution Approach 2:
The retainer bracket acts as an intermediary component that provides secure retention without permanent attachment. The detachable coupling to retainer pegs allows the bracket to hold batteries firmly during operation while enabling quick release when access is needed, balancing stability and accessibility requirements
3Adaptability or versatility
If modular battery trays are used, then scalability is improved, but device complexity increases
Solution Approach 1:
The side panels are designed with integrated flanges that serve multiple functions: providing structural support, enabling stacking of battery trays, and creating alignment interfaces for adjacent trays. The retainer pegs and brackets provide both retention and positioning functions. This multi-functionality reduces the number of separate components needed, maintaining simplicity while enabling scalable configurations
Data Source
AI summary
In accordance with presently disclosed embodiments, a front access battery tray is provided. In one embodiment, the front access battery tray comprises a base having a front edge, two side edges, and a back edge; a pair of side panels extending substantially perpendicularly from the side edges of the base, each side panel comprising a top edge and an outer surface, wherein at least one retainer peg extends away from each outer surface; a pair of flanges extending from the top edge of each side panel, each flange comprising an inner lip; a back panel extending substantially perpendicularly from the back edge of the base; and a retainer bracket detachably coupled to at least one of the retainer pegs on the side panels.