Modular Battery Housing with Compensation Elements
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Solution Overview
Problem
The existing modular battery systems for motor vehicles require different-sized battery housings due to varying numbers of battery cells, leading to increased production costs and safety hazards from unfilled spaces, which are uneconomical and pose risks during vehicle use.
Innovation Solution
A modular system where different-sized battery modules are arranged in a standardized battery housing, using compensation elements to fill empty spaces, ensuring a space-filling arrangement and enhanced safety, while allowing for uniform design and reduced production costs by using identical housing sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different-sized battery housings are produced to accommodate varying numbers of battery cells, then the battery can be adapted to different power requirements, but production costs increase and safety hazards arise from unfilled spaces
Solution Approach 1:
The battery system is segmented into standardized battery modules (each containing a fixed number of battery cells) that can be combined in different quantities to achieve different total capacities. This allows adaptation to different power requirements without requiring different housing sizes - the same housing accommodates different numbers of identical modules.
Solution Approach 2:
Compensation elements are introduced as intermediary components to fill the empty space between the battery modules and the housing walls. These compensation elements act as mediators that enable the use of a standardized housing size while accommodating varying numbers of battery modules, thus resolving the contradiction between adaptability and manufacturing simplicity.
2Adaptability or versatility
If different-sized battery housings are produced to accommodate varying numbers of battery cells, then the battery can be adapted to different power requirements, but safety hazards arise from unfilled spaces
Solution Approach 1:
The battery system is segmented into standardized battery modules (each containing a fixed number of battery cells) that can be combined in different quantities to achieve different total capacities. This allows adaptation to different power requirements without requiring different housing sizes - the same housing accommodates different numbers of identical modules.
Solution Approach 2:
Compensation elements are introduced as intermediary components to fill the empty space between the battery modules and the housing walls. These compensation elements act as mediators that enable the use of a standardized housing size while accommodating varying numbers of battery modules, thus resolving the contradiction between adaptability and manufacturing simplicity.
3Power
If battery modules of different sizes are used to meet specific power requirements, then the power can be increased by adding one more battery cell, but the battery housing size must be adapted correspondingly
Solution Approach 1:
The battery system is segmented into standardized battery modules (each containing a fixed number of battery cells) that can be combined in different quantities to achieve different total capacities. This allows adaptation to different power requirements without requiring different housing sizes - the same housing accommodates different numbers of identical modules.
Solution Approach 2:
A single standardized battery housing design serves multiple functions by accommodating different quantities of identical battery modules. This universal housing design can support various power requirements through modular configuration, eliminating the need for multiple housing size variants.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The modular system achieves economic viability and increased safety by allowing uniform battery housing production, reducing production costs, and protecting the battery from external forces through the use of compensation elements, which can be resilient or have a spring device for deformation.
Implementation Method 1
The compensation element is resilient or has a spring device arranged between the compensation element and the battery housing or between the compensation element and an adjacent battery module, so that the compensation element can be deformed
Data Source
AI summary
A modular system (1) for a battery (2) has a battery housing (3), at least one first battery module (4) having a number n of battery cells (5) and at least one further battery module (6) having a higher number n+x or a lower number n−x of battery cells (5) can be arranged in the battery housing (3). In this case, one first battery module (4) can be arranged in a space-filling manner within the battery housing (3), or one further battery module (6) together with at least one compensation element (7) of the modular system (1) can be arranged in a space-filling manner within the battery housing (3).