Modular RESS Containment Layout for In-Vehicle Service Access

Solution Overview

Problem

Existing rechargeable energy storage systems (RESS) require the complete removal from a vehicle for servicing individual elements, incurring labor and other costs.

Innovation Solution

A multi-cell RESS containment system with a modular design, featuring separate compartments for power electronics, battery cells, and an auxiliary power module, allowing for independent access and servicing without removing the entire system from the vehicle.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of repair

If the complete RESS is removed from the vehicle for servicing individual elements, then servicing can be performed, but labor costs and time are increased

Engineering Contradiction:

Improveservicing capabilityVSAvoidlabor time

Core Design Contradiction:

Ease of repairVSLoss of time

Solution Approach 1:

The containment system is divided into multiple separate compartments, each housing different RESS elements (battery cells, power electronics, auxiliary power module). Each compartment has its own access mechanism, allowing technicians to service individual elements by opening only the relevant compartment rather than removing the entire RESS from the vehicle.

Inventive Principle:

Principle #1Segmentation

2Ease of repair

If the complete RESS is removed from the vehicle for servicing, then individual elements can be serviced, but labor costs are increased

Engineering Contradiction:

Improveservicing capabilityVSAvoidlabor cost

Core Design Contradiction:

Ease of repairVSEase of manufacture

Solution Approach 1:

The containment system is divided into multiple separate compartments, each housing different RESS elements (battery cells, power electronics, auxiliary power module). Each compartment has its own access mechanism, allowing technicians to service individual elements by opening only the relevant compartment rather than removing the entire RESS from the vehicle.

Inventive Principle:

Principle #1Segmentation

3Strength

If the RESS is designed as a single integrated unit, then structural integrity is maintained, but servicing requires complete removal

Engineering Contradiction:

Improvestructural integrityVSAvoidservicing accessibility

Core Design Contradiction:

StrengthVSEase of repair

Solution Approach 1:

The containment system is divided into multiple separate compartments, each housing different RESS elements (battery cells, power electronics, auxiliary power module). Each compartment has its own access mechanism, allowing technicians to service individual elements by opening only the relevant compartment rather than removing the entire RESS from the vehicle.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The containment system uses nested compartments where smaller compartments are positioned within or adjacent to larger containment structures. This nested arrangement maintains overall structural integrity while providing independent access to individual elements through separate access panels on each compartment.

Inventive Principle:

Principle #7Nested doll (Nesting)

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

Enables efficient servicing of individual components within the RESS without dismounting the entire system, reducing labor costs and improving maintenance efficiency.

Implementation Method 1

The plurality of battery cells connect to the plurality of power electronic devices via a high-voltage DC power bus that is arranged to pass through the first slot

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

the floor plate being fabricated from a material having a high coefficient of high thermal conductivity

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

the fluidic bath being arranged to partially immerse the plurality of battery cells in a coolant fluid

Methodology Applied

Scientific EffectConvection cooling: Convection

Data Source

PatentUS12237476B2Containment system for a multi-cell rechargeable energy storage device

Publication Date: 2025.02.25 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A containment system for a rechargeable energy storage device (RESS) is described includes an enclosure having a first compartment adjoining a second compartment. The first compartment is arranged to house a plurality of power electronics devices, and the second compartment is arranged to house a plurality of battery cells. The second compartment includes a tub that defines a bottom portion, and a floor plate. The tub includes opposed end walls and opposed sidewalls. A top plate is arranged overtop of the first compartment and the second compartment. A first one of the end walls and the top plate define a first slot between the first compartment and the second compartment. A first removable panel is arranged to enclose the first compartment. The plurality of battery cells connect to the plurality of power electronics devices via a high-voltage DC power bus that is arranged to pass through the first slot.