Segmented Insulating Mother Board for Flexible Battery Module Assembly
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Solution Overview
Problem
The existing battery module assembly technologies face challenges in accommodating different numbers and standards of single batteries due to limited flexibility in insulating mother boards, which restricts the optimization of energy density and mileage of electric vehicles.
Innovation Solution
An insulating mother board design featuring moveable connection boards with adjustable connection holes and a conductive connection strip system that allows for flexible assembly of various battery configurations, including different numbers and standards, using a combination of protrusions and grooves for stable connections and a structural adhesive for secure fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple single batteries are adopted to form a battery module, then the total power of the system is increased, but the flexibility of the insulating mother board is too low to achieve assembly of different numbers and standards of single batteries
Solution Approach 1:
The insulating mother board is divided into a first end insulating board, a second end insulating board, and multiple middle insulating boards. These segmented components can be selectively assembled to create insulating mother boards of different lengths and configurations, enabling adaptation to various battery module requirements while maintaining electrical insulation and structural integrity.
Solution Approach 2:
The insulating mother board design incorporates universal connection features including protrusions and grooves that can accommodate different numbers and standards of single batteries. The standardized connection holes and insulating structures allow the same basic components to serve multiple assembly configurations, achieving both high power and flexibility.
2Quantity of substance
If the number of batteries is increased to improve energy density, then the total power is increased, but the weight and size of the system are also increased
Solution Approach 1:
Multiple insulating boards are connected through protrusions and grooves to form an integrated insulating mother board structure. This merging of separate insulating components into a unified assembly reduces the total number of separate parts, decreases overall weight, and simplifies the battery module construction while maintaining adequate insulation for multiple batteries.
Solution Approach 2:
The insulating mother board is designed with moveable connection capabilities through protrusions and grooves, allowing flexible assembly and disassembly. This dynamic design enables optimization of battery arrangement to maximize energy density without requiring excessive structural material, thereby reducing weight while accommodating variable numbers of batteries.
3Reliability
If a rigid insulating mother board structure is used to ensure safety and stability, then the structural integrity is maintained, but the adaptability to different battery configurations is reduced
Solution Approach 1:
The insulating mother board is segmented into modular components (end boards and middle boards) that can be selectively combined. This segmentation maintains structural integrity through standardized connection features while enabling adaptation to different battery configurations by varying the number and arrangement of middle insulating boards.
Solution Approach 2:
The connection mechanism between insulating boards incorporates moveable elements through protrusions and grooves that allow flexible assembly. This dynamic connection design ensures stable and reliable joints while enabling the insulating mother board to adapt to various battery numbers and standards, reconciling reliability with versatility.
Data Source
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AI summary
An insulating mother board is provided. Insulating harness mother board assemblies for different length requirements may be implemented by combining a variable number of middle insulating boards (2), that is, flexibility of assembling a module for different requirements is improved on the premise of not adding categories of components. A first end insulating board (1), a middle insulating board (2) and a second end insulating board (3) are moveably connected, an arbitrary number of middle insulating boards (2) can be arranged by arranging the first end insulating board (1) and the second end insulating board (3) on two ends of the insulating mother board respectively. There may be an arbitrary number of connection holes (303) on the first end insulating board (1), the middle insulating board (2) and the second end insulating board (3). Each connection hole (303) corresponds to one single battery (6), in this way, an assembly of different numbers of single batteries (6) can be achieved. An insulating harness mother board assembly and a battery module including the insulating mother board are provided.