Modular Battery Module Assembly for Flexible Vehicle Power Output
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Solution Overview
Problem
The complexity and inefficiency of assembling battery modules with high capacity and large area requirements, which increases manufacturing costs and time due to the need for multiple battery cells and frequent housing remanufacturing for varying power demands.
Innovation Solution
A battery module design featuring multiple sub-modules with a connection member, upper and lower covers, and insulating and end covers, allowing for simplified and stable assembly by interposing the connection member between sub-modules and using fastening members to secure the structure, enabling flexible power output and reduced assembly time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of battery cells is increased to achieve high capacity and large area, then the power output is improved, but the assembly complexity and required time increase
Solution Approach 1:
The battery module is divided into multiple sub-modules, each containing a set of battery cells arranged in a standardized configuration. This segmentation allows the overall battery module to achieve high capacity through modular assembly rather than complex individual cell arrangements, thereby reducing assembly complexity while maintaining high power output capability.
Solution Approach 2:
Multiple sub-modules are nested within a common housing structure with shared connection members and insulation components. The sub-modules contain battery cells that are nested within standardized frames and connected through common busbars. This nested arrangement reduces the number of external connection components needed, simplifying the overall assembly process while scaling power output.
2Power
If the number of battery cells is increased to achieve high capacity, then the power output is improved, but the assembly time increases
Solution Approach 1:
By segmenting the battery module into standardized sub-modules, each sub-module can be pre-assembled and tested independently before final integration. This reduces the overall assembly time for high-capacity modules, as multiple sub-modules can be prepared in parallel and quickly integrated using standardized connection interfaces, thereby scaling power output without proportionally increasing assembly time.
Solution Approach 2:
The sub-modules are designed with pre-integrated connection members, insulation covers, and busbar assemblies that are prepared in advance. This preliminary configuration of essential components within each sub-module eliminates the need for time-consuming on-site assembly of electrical connections and insulation, significantly reducing total assembly time while maintaining high power output capability.
3Power
If the housing is remanufactured to accommodate different numbers of battery cells, then the power output is adjusted, but the manufacturing cost increases
Solution Approach 1:
The housing and connection member structures are designed with universal dimensions and standardized interfaces that can accommodate different numbers and configurations of sub-modules. This universality allows the same housing design to serve multiple power output requirements by simply varying the number of sub-modules installed, eliminating the need for costly remanufacturing of housings for different power levels and enabling flexible power scaling.
4Weight of stationary object
If the battery module structure is simplified to reduce weight, then the manufacturing cost is reduced, but the structural stability may be compromised
Solution Approach 1:
The connection members and support structures are designed with optimized local thickness and material distribution, providing enhanced structural stability at critical load-bearing locations while using thinner, lighter materials in non-critical areas. This local quality optimization maintains the necessary structural stability for supporting battery cells and withstanding mechanical stresses, while minimizing the overall weight of the battery module structure.
Solution Approach 2:
The battery module structure utilizes composite materials combining high-strength, low-density materials such as aluminum alloys for connection members and support frames. These composite materials provide the necessary structural stability and mechanical strength to support the battery cells and withstand operational stresses, while significantly reducing the overall weight compared to traditional solid metal structures, thereby achieving both weight reduction and stability maintenance.
Data Source
AI summary
An eco-friendly power source, such as a battery module is provided for a transportation vehicle and includes a plurality of cell assemblies including a first cell assembly and a second cell assembly each including a plurality of battery cells; a connection member connected to the first cell assembly and the second cell assembly, respectively; a lower cover supporting the plurality of cell assemblies; and end cover spaced apart from the connection member, wherein the first cell assembly and the second cell assembly have at least one side opposing the connection member and the other side opposing the end cover.