Modular Battery Module with Deformable Support for Irregular Spaces
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Solution Overview
Problem
Existing battery modules for electric energy storage systems in electric drive vehicles face challenges in adapting to irregular shapes and have complex manufacturing processes, leading to poor mechanical robustness and high production costs.
Innovation Solution
A battery module design featuring modular, thermally conductive and electrically insulating containers with lithium-ion batteries arranged in series and parallel, supported by robust yet deformable structures, allowing for complex shapes and simplified manufacturing through plastic moulding and easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If chemical batteries are arranged in a plastic support matrix, then mechanical support is provided, but the storage system cannot adapt to irregular shapes
Solution Approach 1:
The battery system is divided into multiple modular battery modules, each containing a subset of batteries. These modules can be independently configured and arranged in different patterns to fit irregular spaces within the vehicle, providing adaptability without requiring complex custom structures for each application.
Solution Approach 2:
The patent employs support structures with flexible design capabilities, allowing the battery assembly to conform to irregular vehicle spaces. The modular architecture enables the system to be shaped and configured to match available installation spaces rather than requiring fixed rigid structures.
2Reliability
If guide pins and insulating plates are used to close housings, then battery positioning is achieved, but manufacture becomes complex and mechanical robustness is poor
Solution Approach 1:
The support body integrates multiple functions into a single structural element: it provides mechanical support for the batteries, positions the connection plates, and structures the overall module assembly. This consolidation eliminates the need for separate guide pins and insulating plates, simplifying manufacturing while improving structural robustness.
Solution Approach 2:
The support body is made from composite materials that provide both mechanical strength and electrical insulation properties in a single component, replacing the previous design that required separate insulating plates and metal guide pins. This composite approach simplifies manufacturing while maintaining or improving mechanical robustness.
3Volume of moving object
If complex shapes are required for space adaptation, then space utilization improves, but manufacturing cost increases
Solution Approach 1:
The system uses standardized modular battery modules that can be combined in different configurations to achieve complex overall shapes while maintaining simple, cost-effective individual module manufacturing. This segmentation allows space adaptation through assembly rather than custom manufacturing of complex shapes.
Solution Approach 2:
The battery modules are designed with universal interfaces and standardized dimensions, allowing the same basic module design to be used in various configurations for different vehicle applications. This universality reduces manufacturing costs by using standardized components while still achieving space adaptation through flexible arrangement.
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 design enables efficient use of available space with complex shapes, simplifies manufacturing, and ensures robustness while being cost-effective, with quick assembly and disassembly for maintenance, and safety features to prevent electrical hazards in accidents.
Implementation Method 1
modular, thermally conductive and electrically insulating containers with lithium-ion batteries
Data Source
AI summary
A battery module for a system for the storage of electrical energy for an electric drive vehicle. The battery module has: a group of chemical batteries arranged parallel to and beside one another; at least two connection plates which rest against opposite ends of the group of chemical batteries so as to electrically connect the poles of the chemical batteries to one another; two support bodies coupled to opposite ends of the group of chemical batteries so as to provide the chemical batteries with a stable mechanical support; two lids, which are coupled to the support bodies so as to create respective collecting chambers having at least one draining opening; and at least two tie rods, which are arranged on opposite sides of the battery module and tie together the lids and the support bodies in a packed manner.