Modular Battery Pack Assembly for Flexible Multi-Side Coupling
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Solution Overview
Problem
Current battery packs lack flexibility in configuring the number of battery modules and processing units, and their appearance, which limits adaptability to various installation spaces and customer needs.
Innovation Solution
A battery pack design that allows for the modular coupling of battery modules and processing units on multiple sides, using coupling members and corner covers to secure and protect components, enabling flexible configuration and improved assembly productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If battery packs use fixed configuration of battery modules and processing units, then manufacturing and assembly are simplified, but adaptability to different power requirements and installation spaces is reduced
Solution Approach 1:
The battery pack is divided into modular components including battery modules (each containing multiple battery cells), processing units, coupling members, and corner covers. These segmented modules can be independently manufactured and then assembled in various configurations to meet different power requirements and installation spaces, resolving the contradiction between adaptability and complexity.
Solution Approach 2:
The coupling members and corner covers are designed as universal components that can be used across different battery pack configurations. The coupling members enable standardized connection between processing units and battery modules, while corner covers provide consistent protection at all corner positions. This universality allows the same components to serve multiple functions in different configurations, enhancing adaptability without proportionally increasing complexity.
2Adaptability or versatility
If battery packs are designed with fixed appearance and configuration, then manufacturing precision and assembly are improved, but flexibility to change number of battery modules and processing units is lost
Solution Approach 1:
The coupling members and corner covers are pre-designed with standardized connection interfaces and geometric features that ensure proper alignment and assembly. The coupling members include predefined attachment points and the corner covers are shaped to fit specific corner configurations, allowing modular components to be assembled with consistent precision across different battery pack configurations without requiring complex real-time adjustments.
3Productivity
If coupling members and corner covers are added to enable modular assembly, then adaptability and productivity are improved, but device complexity and number of components increase
Solution Approach 1:
The coupling members serve multiple functions simultaneously: they mechanically connect processing units to battery modules, provide structural support, and enable electrical connections. The corner covers not only protect corner positions but also contribute to the overall structural integrity and aesthetic appearance. By merging multiple functions into single components, the patent reduces the effective complexity despite adding modular capability.
Solution Approach 2:
The corner covers are designed to be secured to coupling members in a straightforward manner that provides both protection and structural contribution. The self-contained modular design allows components to serve their own protective and structural needs without requiring additional separate elements, improving assembly productivity while limiting the growth of complexity.
Data Source
AI summary
The battery pack includes a battery module; a processing unit which is electrically connected to the battery module and configured to control charge/discharge of the battery module, wherein at least one of the battery module or the processing unit is configured to allow another battery module or another processing unit to be coupled to two or more sides thereof.