Modular Battery Pack Repair via Removable End Frames
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Solution Overview
Problem
Current battery pack modules are difficult to repair, leading to the need for scrapping entire modules when individual components fail, as the frames are not designed for maintenance and repair.
Innovation Solution
The battery pack module design includes end frames with detents for clamps to maintain compression, a ridge for support during transport and repair, and modular components that allow for disassembly and replacement of battery cells, cooling fins, and frames while maintaining electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery cells are welded to a separate interconnect board in frames, then electrical connection is achieved, but repairability deteriorates and entire module must be scrapped when one component fails
Solution Approach 1:
The battery pack is divided into modular sections with individual frames that can be independently removed. Each frame contains specific battery cells and can be separated from the overall structure, allowing repair of individual components without affecting other parts of the system.
Solution Approach 2:
The interconnect board and cooling fin assembly are extracted as separate removable components from the frame structure. This allows these components to be independently replaced or repaired while leaving the battery cells and frame intact, eliminating the need to scrap the entire module.
2Strength
If frames are designed to house cells and cooling fins, then structural support is provided, but access to bottom of frame becomes difficult for repair
Solution Approach 1:
The frame design incorporates removable clamps that can be easily attached and detached. When clamps are removed, the frame structure becomes more accessible for repair work on the bottom side, while maintaining structural integrity during normal operation and transport.
Solution Approach 2:
A repair station with a cradle serves as an intermediary device during repair operations. The cradle supports the battery pack frame from below, providing stable access to the bottom components while maintaining proper orientation and structural support.
3Stability of the object's composition
If clamps are used to maintain compression on battery pack, then structural stability is improved, but access to components is blocked during repair
Solution Approach 1:
The clamps are designed to be dynamically adjustable and removable. During normal operation, clamps maintain compression for stability. During repair, clamps can be quickly removed to provide access to components, and then reattached after repair to restore structural integrity.
Data Source
AI summary
A battery pack is described. One embodiment of the battery pack includes a pair of end frames, the end frames having a top and a bottom and a pair of sides, the end frames having a detent on at least one of the sides of the end frames to receive a clamp; a frame positioned between the pair of end frames, the frame having a top and a bottom and a pair of sides, the frame having a ridge on at least one of the sides of the frame; a plurality of battery cells positioned in the frame and the pair of end frames, the plurality of battery cells electrically connected to each other at the top of the frame; and at least one cooling fin positioned between the battery cells. Methods of repairing battery packs are also described.