Modular Battery Frame Assembly for Scalable Cell Connection Reliability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery pack designs for cylindrical cells face challenges in maintaining structural stability and efficient electrical connections due to the use of adhesives or mechanical retention devices away from the top of the cell, leading to assembly inefficiencies and potential connection failures.
Innovation Solution
A modular battery frame system comprising frame blocks and scaffolds, where each frame block includes individual battery cell frames and electrical collectors, allowing for modifiable size and configuration to accommodate varying numbers of cells, with collectors aggregating cells in series or parallel to adjust voltage and capacity, and fasteners securing the frame blocks to scaffolds for structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesives or mechanical retention devices are used away from the top of the cell, then structural stability is maintained, but assembly efficiency decreases and connection failures may occur
Solution Approach 1:
The battery pack structure is segmented into modular frame blocks that can be independently assembled and connected. Each frame block contains integrated retention features and electrical collectors, allowing for standardized, efficient assembly while maintaining structural integrity through modular connectivity rather than complex adhesive applications.
Solution Approach 2:
The frame blocks serve as intermediary structural elements that provide both mechanical retention and electrical connection functions. These intermediaries eliminate the need for separate adhesives or retention devices by integrating both functions into the frame structure itself, improving assembly efficiency while maintaining reliability.
2Strength
If frame blocks are connected to scaffolds with fasteners, then structural integrity is enhanced, but device complexity increases
Solution Approach 1:
The fastening mechanism is merged with the scaffold and frame block structures themselves. The scaffolds include integrated attachment features that directly engage with frame blocks, combining the fastening function with the structural support function. This reduces the number of separate components and simplifies assembly while maintaining structural integrity.
Solution Approach 2:
The frame blocks and scaffolds are designed with universal, standardized connection interfaces that serve multiple functions: structural support, mechanical fastening, and alignment. This multi-functionality reduces the need for specialized components and simplifies the overall assembly process while ensuring structural integrity.
3Adaptability or versatility
If collectors are configured in multiple configurations, then adaptability for specific applications is improved, but manufacturing complexity increases
Solution Approach 1:
The electrical collectors are designed with dynamic configurability through standardized connection points and modular arrangements. The same collector design can be configured in different patterns (series, parallel, or combinations) by changing the connection topology rather than manufacturing different collector types. This maintains manufacturing simplicity while providing application-specific adaptability.
Solution Approach 2:
The electrical configuration is changed by modifying connection parameters (series/parallel arrangements, connection points) rather than changing the physical collector components themselves. This allows multiple electrical configurations to be achieved using the same manufactured parts, reducing manufacturing complexity while maintaining adaptability for different voltage and capacity requirements.
Data Source
AI summary
A modular battery frame is disclosed. The modular battery frame includes one or more frame blocks and scaffolds to which the frame blocks attach. Each frame block includes individual battery cell frames and electrical collectors. The individual frame blocks are connected to one another. The collectors to electrically connect battery cells and the battery cells in frame blocks. The size of the modular battery frame is modifiable by changing the length of the scaffolds, to accommodate a predetermined number of frame blocks. The frame blocks are modifiable. The disclosure also provides a battery module. The battery cells are housed in the individual battery cell frames and connect to the collectors. The scaffolds attach to the frame blocks. The battery module also includes a battery management system positioned on a frame block. The voltage and capacity of the battery module are modifiable by changing the length of the scaffold profiles.