Modular EV Battery Pack for In-Place Module Servicing

Solution Overview

Problem

Existing electrified vehicles require the entire battery pack to be removed for servicing individual modules, which is inconvenient and inefficient.

Innovation Solution

A modular battery pack configuration with individually removable modules, a disconnect switch to deenergize the pack, and a latch assembly to open the access cover, allowing independent module servicing without removing the entire pack.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the entire battery pack is removed for servicing individual modules, then complete battery pack service is ensured, but vehicle downtime increases and maintenance complexity increases

Engineering Contradiction:

Improvebattery pack service completenessVSAvoidvehicle downtime

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The battery pack is divided into multiple independently removable modules, each containing a subset of battery cells. This segmentation allows service personnel to remove and service only the specific module that requires maintenance, rather than removing the entire battery pack. The modules are designed with standardized interfaces for electrical, fluid, and mechanical connections, enabling quick detachment and reattachment procedures that significantly reduce vehicle downtime while maintaining service completeness.

Inventive Principle:

Principle #1Segmentation

2Reliability

If the entire battery pack is removed for servicing individual modules, then complete battery pack service is ensured, but maintenance complexity increases

Engineering Contradiction:

Improvebattery pack service completenessVSAvoidmaintenance complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The battery pack is divided into multiple independently removable modules, each containing a subset of battery cells. This segmentation allows service personnel to remove and service only the specific module that requires maintenance, rather than removing the entire battery pack. The modules are designed with standardized interfaces for electrical, fluid, and mechanical connections, enabling quick detachment and reattachment procedures that significantly reduce vehicle downtime while maintaining service completeness.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces a disconnect switch as an intermediary device that electrically isolates the battery pack from the vehicle's electrical system before module removal. This intermediary component ensures safety during maintenance operations by preventing electrical shock or short circuits, while also providing a clear visual indicator that the system is de-energized. The disconnect switch simplifies the maintenance process by providing a straightforward safety procedure rather than requiring complex electrical isolation methods.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of operation

If the access cover is opened without deenergizing the battery pack, then quick access to modules is achieved, but electrical safety is compromised

Engineering Contradiction:

Improveaccess speedVSAvoidelectrical shock risk

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent requires the disconnect switch to be activated before opening the access cover, establishing a preliminary safety action sequence. This preliminary de-energization step ensures that the battery pack is electrically isolated before any physical access is gained to the modules. The system is designed so that the disconnect switch must be in the OFF position for the access cover to be opened, embedding the safety procedure into the operational sequence and preventing accidental exposure to live electrical components.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces a disconnect switch as an intermediary device that electrically isolates the battery pack from the vehicle's electrical system before module removal. This intermediary component ensures safety during maintenance operations by preventing electrical shock or short circuits, while also providing a clear visual indicator that the system is de-energized. The disconnect switch simplifies the maintenance process by providing a straightforward safety procedure rather than requiring complex electrical isolation methods.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12515509B2Electrified vehicle including battery pack with modular configuration

Publication Date: 2026.01.06 FORD GLOBAL TECH LLC

AI summary

An electrified vehicle may include an underbody. An electrified vehicle may include a battery pack mounted to the underbody, wherein the battery pack includes a plurality of modules, wherein each module includes an array of battery cells, and wherein each module is individually removable from the battery pack without requiring removal of the battery pack from the underbody.