Modular Battery Tray With Conductive Carrier Elements
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Solution Overview
Problem
Current battery configurations for high-temperature applications are custom and complex, making them difficult to manufacture and maintain, as they require unique interconnect patterns and impact thermal, cooling, and routing aspects, leading to increased design and service challenges.
Innovation Solution
A modular electrochemical device configuration featuring elongate electrochemical cells with conductive carrier elements and insulating strips, allowing for easy assembly and connection of cells in series or parallel, with modular cell trays and breakable or flexible connectors for flexible configuration and easy maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If custom battery interconnect patterns are used for each application, then the battery can achieve required voltage and capacity specifications, but the manufacturing complexity and design time increase significantly
Solution Approach 1:
The patent implements a universal battery interconnect structure where a single tray design with standardized carrier elements can accommodate multiple cell types and configurations. The interconnect tray includes reusable carrier elements that can be selectively positioned to create different electrical connections (series, parallel, or combinations) without requiring custom tooling or design changes for each application.
2Adaptability or versatility
If custom battery configurations are developed for new applications, then specific performance requirements are met, but manufacturing and maintenance difficulty increase
Solution Approach 1:
The battery assembly is segmented into modular components: individual cells, carrier elements that hold multiple cells, trays that contain carrier elements, and end plates. This segmentation allows each component to be manufactured independently using standardized processes, and then assembled in various configurations to meet different application requirements without increasing overall manufacturing complexity.
Solution Approach 2:
The system incorporates dynamic reconfigurability through movable carrier elements within the tray. The carrier elements can be repositioned along the tray to change electrical connections between cells, allowing the same physical assembly to adapt to different voltage and capacity requirements while maintaining simple manufacturing processes.
3Ease of manufacture
If fixed battery configurations are used, then manufacturing is simplified, but adaptability to different applications is reduced
Solution Approach 1:
The interconnect tray incorporates movable carrier elements that can be repositioned to create different electrical configurations. This dynamic capability allows a single standardized tray design to serve multiple applications with different voltage and capacity requirements, maintaining manufacturing simplicity while providing application adaptability.
4Reliability
If complex custom configurations are implemented, then specific battery requirements are satisfied, but serviceability and maintenance time increase
Solution Approach 1:
The modular segmented design allows individual carrier elements or cells to be independently accessed and replaced within the tray. If a cell or carrier element fails, it can be removed and replaced without disassembling the entire battery assembly, significantly improving serviceability compared to fixed configurations where changes require complete disassembly.
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
This modular configuration simplifies manufacturing and maintenance by enabling rapid reconfiguration of battery voltage and capacity, reducing complexity and improving serviceability while maintaining reliable electrical connections at high temperatures.
Implementation Method 1
The second electrode body of each cell is welded to the carrier element at a corresponding aperture of the first plurality of apertures
Data Source
AI summary
A cell module and modular cell tray apparatus for a modular electrochemical device that are more easily manufactured and serviced. A cell module is provided having a plurality of electrochemical cells. The cell module includes an electrically conductive carrier element having a plurality of apertures, wherein each aperture is configured to accept a top portion of an electrode body of an electrochemical cell. A modular cell tray apparatus is provided having a plurality of the cell modules. The cell tray apparatus includes an electrically insulating tray having rows of cell receptacles to accept the cell modules. A modular electrochemical device is provided having a plurality of the cell tray apparatuses. The modular electrochemical device includes a plurality of electrical connectors configured to electrically connect the cell modules within a cell tray apparatus, and to electrically connect the cell tray apparatuses to each other.