Modular Battery Frame With Bottom-Removable Battery Boxes
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Solution Overview
Problem
Conventional battery packs in electrified vehicles are large, heavy, and require specialized equipment and training for serviceability, making them difficult to maintain and upgrade.
Innovation Solution
A battery frame with a flat, rectangular outer shape and a height shorter than its length and width, featuring removable battery boxes that can be installed or replaced from below, allowing for independent service and maintenance without removing the entire battery pack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional battery packs are used, then energy storage capacity is achieved, but serviceability and ease of maintenance deteriorate due to large size and weight requiring special equipment and training
Solution Approach 1:
The battery pack is divided into multiple individual battery boxes that can be independently removed and replaced. Each battery box contains one or more battery cells and can be serviced separately, eliminating the need to handle the entire heavy battery pack during maintenance operations.
2Quantity of substance
If conventional battery packs are used, then energy storage capacity is achieved, but ease of operation deteriorates due to large size and weight
Solution Approach 1:
The battery system is segmented into modular battery boxes that are individually removable from the battery frame. This allows technicians to handle and replace single battery boxes rather than the entire large and heavy battery pack, significantly improving ease of operation.
3Quantity of substance
If conventional battery packs are used, then energy storage capacity is achieved, but device complexity increases due to requirement for special equipment and training
Solution Approach 1:
By segmenting the battery pack into individually removable battery boxes, the system eliminates the need for specialized heavy-lifting equipment and extensive training. Standard tools and procedures can be used to service individual boxes, reducing overall service equipment complexity.
4Ease of repair
If battery boxes are made removable from below the outer frame, then ease of repair is improved, but structural design complexity increases
Solution Approach 1:
The battery boxes are designed to be removable from below the outer frame, utilizing the vertical dimension for access. This allows service personnel to reach up and remove battery boxes from underneath, simplifying repair operations while maintaining a compact overall structure.
Data Source
AI summary
A battery frame for holding one or more battery boxes includes an outer frame surrounding an interior space and formed from a plurality of structural members including first rails extending parallel to and spaced apart from one another and second rails between the first rails and perpendicularly thereto. The outer frame defines a top extending in a flat plane and a bottom. Each of the first rails includes a mounting flange extending outwardly away from the interior space for holding the battery frame to a vehicle structure. One or more battery boxes are disposed within the interior space of the outer frame and are removable from below the outer frame with the outer frame mounted within a vehicle. Support members and cross-beams provide structural rigidity, distribute or absorb crash loads, and hold one or more of the battery boxes within the battery frame.