Modular Battery Carrier with Detachable Component Carriers
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Solution Overview
Problem
Existing battery modules require disassembly of the entire system to replace or maintain individual components, which is inefficient and costly, especially in applications like electric vehicles where modularity and interchangeability are crucial.
Innovation Solution
A battery module carrier with detachable component carriers that include a control electronics assembly and battery submodules, allowing for individual attachment and detachment from a carrier frame, providing modular connectivity for signal, power, and coolant transmission, and enabling easy replacement and maintenance without dismounting the entire module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If battery modules are constructed in a block design with all cells coupled to a common current collector structure, then the structural integrity and electrical connectivity are improved, but the ease of repair and maintenance deteriorates because the entire system must be disassembled to replace individual components
Solution Approach 1:
The battery system is divided into modular battery modules, each with its own current collector structure. This segmentation allows individual modules to be independently accessed, removed, and replaced without disassembling the entire battery system, thereby improving ease of repair while maintaining structural integrity through standardized module interfaces
2Ease of manufacture
If battery modules are constructed in a block design with all cells coupled to a common current collector structure, then the manufacturing simplicity is improved, but the ease of manufacture of individual components deteriorates due to increased complexity
Solution Approach 1:
The battery system is divided into standardized battery modules that can be manufactured independently and then assembled into the complete system. This segmentation reduces device complexity at the component level while maintaining manufacturing simplicity through standardized interfaces and modular assembly processes
Solution Approach 2:
Standardized current collector structures and module interfaces are designed to be universal across different battery modules. This universality allows the same component designs to be reused throughout the system, simplifying manufacturing processes while managing overall system complexity through standardization
3Stability of the object's composition
If the entire battery module must be disassembled to replace individual components, then the structural stability is maintained, but the loss of time for maintenance and replacement increases
Solution Approach 1:
The battery system is segmented into independently replaceable modules with standardized interfaces. This allows individual modules to be quickly swapped out without affecting the structural stability of the remaining system, significantly reducing maintenance time while preserving overall structural integrity
Solution Approach 2:
Battery modules are pre-assembled with complete current collector structures and electrical connections before installation into the final system. This preliminary assembly ensures that when a module needs replacement, it can be quickly swapped as a complete unit, minimizing downtime while the modular design maintains structural stability
Data Source
AI summary
A battery module carrier includes a carrier frame configured to accommodate a first component carrier and a second component carrier. The first component carrier includes a control electronics assembly and a signal port, and the second component carrier is configured to accommodate a battery submodule. The carrier frame is configured to provide an external electronic connection to the first component carrier via the signal port, and each of the first component carrier and the second component carrier are configured to be individually attached and detached from the carrier frame.