Modular Battery Pack Structure for Sealed Easy Replacement
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Solution Overview
Problem
Existing battery designs require the entire battery to be replaced when faulty, leading to high maintenance costs and difficulty due to the sealed nature of the battery case.
Innovation Solution
A battery design featuring detachable battery modules mounted to a load-bearing bracket, allowing individual module replacement and maintenance without opening an external case, with detachable connections and integrated heat management systems for improved stability and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery is made into a sealed battery pack with all cells stacked in a large battery case, then the battery structure is compact and sealed, but maintenance becomes difficult and the entire battery must be replaced when faulty, resulting in high maintenance costs
Solution Approach 1:
The battery is divided into multiple independent battery modules (first battery module, second battery module, etc.), each with its own shell and battery cells. These modules are detachably mounted on a load-bearing bracket, allowing individual modules to be accessed, maintained, or replaced without opening the entire battery case or affecting other modules. This segmentation resolves the contradiction by maintaining overall battery reliability while enabling easy maintenance of individual modules.
2Reliability
If the entire battery needs to be replaced when faulty, then battery reliability is maintained, but maintenance costs increase significantly
Solution Approach 1:
By segmenting the battery into independent modules that can be individually replaced, the system maintains reliability (the battery continues to function with remaining good modules) while reducing loss (only the faulty module needs replacement, not the entire battery). This directly addresses the contradiction between maintaining reliability and minimizing maintenance costs.
3Device complexity
If all battery cells are accommodated in a sealed space defined by the battery case, then the battery structure is simplified, but maintenance operations require opening the entire case, increasing maintenance complexity
Solution Approach 1:
The battery structure is segmented into multiple modules, each maintaining its own sealed space for battery cells. This allows the overall structure to remain relatively simple while enabling maintenance operations on individual modules without opening the entire battery case, thus reducing maintenance complexity while preserving structural simplicity.
Solution Approach 2:
The load-bearing bracket acts as an intermediary structure that holds the battery modules in place while allowing for easy installation and removal of individual modules. This intermediary structure enables maintenance access to individual modules without compromising the overall battery structure, resolving the contradiction between structural simplicity and ease of maintenance.
Data Source
AI summary
A battery and a power-consuming device are provided. The battery includes a load-bearing bracket and a plurality of battery modules. The battery modules are mounted to the load-bearing bracket, and at least one of the battery modules is detachably mounted. This configuration allows for flexible installation and replacement of battery modules, improving serviceability and adaptability of the battery system in the power-consuming device.