Modular Battery Pack Layout for Scalable Capacity Expansion
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Solution Overview
Problem
Existing battery packs face challenges in easily adjusting capacity and increasing or decreasing the number of cells without requiring new dies and molds, leading to high manufacturing costs and limited flexibility in size and capacity configurations.
Innovation Solution
A modular battery pack design comprising a base pack and add-on packs, where cylindrical battery cells are connected in series and stacked with parallel connections, using busbars and coupling terminals for electrical and physical coupling, allowing easy expansion and contraction of capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of battery cells is changed to adjust capacity, then the battery pack can be adapted to different capacity requirements, but new dies and molds must be manufactured increasing manufacturing costs
Solution Approach 1:
The battery pack is divided into modular units (base pack and add-on packs) that can be independently manufactured using the same dies and molds. Each module contains a standardized number of battery cells (e.g., 5 cells per pack), allowing capacity adjustment by combining different numbers of modules without requiring new manufacturing tools.
Solution Approach 2:
The base pack and add-on packs use identical housing designs, coupling mechanisms, and electrical connection interfaces. This universal design allows the same dies and molds to produce multiple configurations, reducing manufacturing costs while enabling flexible capacity adjustment through modular combination.
2Adaptability or versatility
If the housing is changed to accommodate different numbers of battery cells, then the battery pack can fit different cell configurations, but the housing design becomes complex and difficult to modify
Solution Approach 1:
Instead of designing a single complex housing to accommodate varying cell numbers, the system segments the battery pack into standardized modules. Each module has a fixed, simple housing design that accommodates a specific number of cells (e.g., 5 cells), and multiple modules are stacked to achieve different total capacities.
Solution Approach 2:
Multiple identical housing units (base pack and add-on packs) are combined through standardized coupling mechanisms to create larger battery assemblies. This merging approach maintains simple individual housing designs while achieving configuration flexibility through combination.
3Adaptability or versatility
If additional auxiliary battery packs are connected to increase capacity, then the electrical energy can be increased, but the connection method becomes complex and unreliable
Solution Approach 1:
Multiple battery packs are electrically connected in parallel through standardized coupling terminals that integrate both electrical and mechanical connection functions. This unified coupling mechanism ensures reliable connections when combining base packs and add-on packs to increase electrical energy.
Solution Approach 2:
The coupling terminal serves multiple functions simultaneously: electrical connection, mechanical attachment, and alignment. This multi-functional design simplifies the connection process and enhances reliability when expanding battery capacity by adding multiple packs.
Data Source
AI summary
Discussed is a modular battery pack including a base pack having two or more cylindrical battery cells connected to each other in series, the base pack having a cuboidal shape, and at least one add-on pack having two or more cylindrical battery cells connected to each other in series, the add-on pack having a cuboidal shape. The two or more cylindrical battery cells are disposed side by side in parallel in each of the base pack and the add-on pack, the base pack and the add-on pack are disposed such that side surfaces of the two or more cylindrical battery cells face each other, and the base pack and the add-on pack are connected to each other in parallel. Accordingly, add-on packs may be connected to the base pack in parallel without limit to number to allow easy and simple increase in a capacity of the modular battery pack.