Interlocking Battery Modules for Scalable Tool-Free Energy Storage
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Solution Overview
Problem
Existing solar power systems with battery storage face challenges in scalability, portability, and ease of installation, as they often require permanent installations and lack modular and expandable solutions for off-grid applications.
Innovation Solution
A modular energy storage system comprising stackable and interlocking modules with mechanical and electrical coupling interfaces, allowing for easy reconfiguration and expansion without tools, featuring automatic electrical connections and secure latching to prevent accidental dislodging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a cabinet-sized battery system is used to store significant amount of energy, then energy storage capacity is improved, but portability and ease of installation deteriorate due to permanent installation requirements
Solution Approach 1:
The battery system is divided into multiple modular units, each containing a subset of battery cells and associated electrical components. These modules can be independently handled, transported, and installed, then combined through stacking to achieve the desired total energy storage capacity. This segmentation resolves the contradiction by enabling portable, easy-to-install individual modules while allowing scalable energy storage when stacked together.
Solution Approach 2:
The system transitions from a single large cabinet-based storage unit to a vertical stacking arrangement of multiple smaller modules. By utilizing the vertical dimension through stacking, the system achieves significant energy storage capacity while maintaining the portability and ease of installation of individual smaller modules, effectively resolving the contradiction between storage capacity and operational ease.
2Ease of operation
If a modular stackable system is used to improve portability and ease of installation, then ease of operation is improved, but system complexity increases due to multiple modules and coupling interfaces
Solution Approach 1:
Each modular unit integrates multiple functions including battery cells, electrical components, mechanical coupling interfaces, and alignment features into a single consolidated module. This merging of components within each module reduces the overall system complexity by eliminating the need for separate handling and assembly of individual components, while still maintaining portability and ease of installation through the modular stacking approach.
3Manufacturing precision
If manual alignment and connection of modules is required, then manufacturing precision is improved, but installation time and productivity deteriorate
Solution Approach 1:
The modular units incorporate self-aligning mechanical coupling interfaces with integrated alignment features such as guide rails, positioning pins, or tapered surfaces. When modules are stacked, these features automatically guide and align the modules with each other, ensuring precise mechanical and electrical connections without requiring manual alignment operations. This self-service alignment mechanism simultaneously achieves high manufacturing precision and rapid installation, resolving the contradiction between alignment precision and installation productivity.
Data Source
AI summary
A modular energy storage system includes a plurality of modules removably coupled into a stack and each including electrical components that together form the energy storage system. The plurality of modules includes a lower module having a top side defining top alignment features, an upper module having a bottom side defining bottom alignment features corresponding with the top alignment features to position the upper module on top of the lower module, and wherein the upper module is stacked on the lower module and the upper and lower modules are electrically coupled.